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Maintenance Schedule
Motorcycle Maintenance
1990 Honda CR 500
VEHICLE ID: JH2PE0209LM90XXXX
Engine: PE02E590XXXX
Date of purchase: July 7, 1997.
July 12, 1997 Maintenance
·         Oil change 10w-40
·         Air cleaner
·         Head set lubed
·         Cleaned carb
·         New chain ring (51t)
13-Jul-97
1 hour ride time
July 19 - 20 Clear Creek
·         5 hours ride time
·         Used approx. 5 gallons of gas
·         Replaced brake lever
·         Lost seat bolts
·         Tire pressure Front: 16psi, Rear: 15psi
29-Jul-97
·         Changed oil Castrol 10w-40
·         new spark plug
·         top off coolant
·         pulled sub-frame
·         Pulled pipe, looked inside cylinder. Looks very clean except for what looks like some light surface rust on about 20% of the cylinder.
4-Aug-97
·         Cleaned air filter and reinstalled.
·         Cleaned out muffler.
·         Repainted sub frame, side number plates and touched up frame.
·         Installed pipe guard.
·         Installed new brake lever.
·         Installed new grips.
8-Aug-97
·         1.5 hours at Metcalf
12-Aug-97
·         New rear tire.
9-Aug-97
·         Cleaned bike
·         Changed oil
·         Lubed chain
·         Inspected air box, looks good for Clear Creek.
Aug 16-17, 1997
·         6.0 hours at Clear Creek
19-Aug-97
·         Serviced air filter.
·         Changed oil used 15w-40.
·         Flushed and replaced coolant, 50/50 mix.
·         Repainted right case covers.
Sept 13-14, 1997
·         6 hours at Clear creek
Sept 22 - Oct 7
·         Relubed front and rear hubs.
·         Relubed head set.
·         Replaced upper and lower shock bearings.
·         Relubed lower linkage.
·         Remover and relubed chain.
·         Replaced front sprocket from 14T to 13T.
·         Replaced carb. Vent tubes (3 ea.).
·         Replaced pipe with FMF Fatty.
·         Repacked silencer.
·         Removed and cleaned carb.
·         Resealed air box front’s seal.
·         Cleaned and reoiled air filter
·         Changed oil (15W-40).
·         Set fork height to 0.60 in. was set at 0.00 in.
·         Changed compression in rear to 13 clicks from H (was 5).
·         Changed rebound in rear to 15 from H.
·         Changed front shocks from 11 clicks from H to 5.
·         Replaced front number plate with 96 model.
Nov 1-2
·         5 hours Clear Creek
15-Nov
·         Cleaned and reoiled air filter.
·         Changed oil (15W-40).
·         Replaced front brake pads.
·         Bleed front brakes.
·         Replaced spark plug.
·         Flushed and replaced coolant, Used approx. 40% anti-freeze and water wetter.
Nov 28-29 1997
·         3 hours Clear Creek (very muddy). Will have to strip down linkage and re-lube the whole bike.
·         Next tire: IRC M5B size 140/80-18 70M
Dec 12 1997
·         Replaced clutch. Repainted cover plate.
·         Re-lubed upper and lower linkage.
·         Re-lubed rear axle.
·         Cleaned air filter.
·         Repainted lower frame.
·         Replaced overflow tube.
Date	was	19-Oct-97	30-Dec-97
Rear Compression from H	5	13	13
Rear Rebound from H		15	15
Front Compression From H	5	11	14
Jan 10 1998
4 hours Clear Creek
Maintenance: Regular stuff
Date	was	30-Dec-97	28-Feb-98
Rear Compression from H	5	13	15
Rear Rebound from H		15	16
Front Compression From H	5	14	15?
28-Feb
3 hours Hollister Hills
·         Installed read brake guard before ride.
4-Mar
3 hours Hollister Hills
14-Mar
·         Changed oil (15W-40).
·         Adj. Chain
·         Cleaned air filter.
March  21-22
6 hours Clear Creek. Hose clamp on radiator hose came loose. Had to remove pipe, silencer and side plate to tighten.
2-Apr-98
·         Changed oil (40W)
·         Cleaned filter
·         Lubed clutch and throttle cables.
·         New rear tire.
·         Re-lubed upper and lower linkage.
·         Re-lubed rear axle.
·         Cleaned air filter.
·         Repainted lower frame.
·         Replaced overflow tube.
·         Replaced spark plug.
·         Removed and cleaned carb, replaced gasket in carb top. Sealed outer edge of carb cap with black RTV.
·         Checked all coolant hoses and clamps.
·         Installed E-Line pipe guard.
2-May-98
Pismo 4 Hours
30-May-98
Clear Creek 6 hours
Aug 21-23, 1998
PiPi 6 hours
Sep-98
·         Top end work done. Bored over .25mm, new piston, rings, rod bearing, rod and clips. Replaced head, barrel and reed cage gaskets. Replaced exhaust gaskets.
·         Bled front and rear brakes.
·         Air filter
·         Oil
·         Replaced left hand radiator.
Oct. 2, 1998
·         1.5 hours at Metcalf. Used this time to break in new rings.
·         Rode 2 easy 10 minute rides, allowing bike to cool for 20-30 minutes in between. Most on grand prix track and parking lot.
·         Rode 1 intermittent 20 minute ride around park, allowed bike to cool off.
·         After that rode bike normally with the guys.
·         Oil
·         Air Filter
Impressions:  Better throttle response, more wheel spin. Vibration level seemed the same at low speed. Used a lot of gas. Went through approx. 2 gallons.
Oct. 11, 1998
·         1.5 hours Hollister hills Hare Ball Scramble
·         New tire Dunlop K695E Desert AT 120/100-18
Jan. 15-17, 1999
Clear Creek 4 hours
March 25-28, 1999
Campaign 99 8 hours
·         Changed oil (40W)
·         Cleaned air filter.
·         Lubed clutch and throttle cables.
·         Re-lubed upper and lower linkage.
·         Re-lubed rear axle.
·         Replaced spark plug.
·         Removed and cleaned carb
·         Checked all coolant hoses and clamps.
12-Sep-99
2 hours Hollister.
·         Changed oil (40W)
·         Cleaned air filter.
18-Mar-00
Hollister Hills 3 hours
·         Changed oil (40W)
·         Cleaned air filter.
May-00
1 hour Clear Creek
Peter thumped his head.
·         Changed oil (40W)
·         Cleaned air filter.
July 1-2, 2000
Forest Hill 8 hours
27-Jan-01
Clear Creek 6 hours
·         Changed oil (40W)
·         Cleaned air filter.
·         Lubed clutch and throttle cables.
·         Re-lubed upper and lower linkage.
·         Re-lubed rear axle.
·         Replaced spark plug.
·         Removed and cleaned carb
·         Checked all coolant hoses and clamps.
Aug  18-19, 2001
Clear Creek 2 hours
Two stink’ in hours of riding cus everyone else’s bike where KOed.
26-Sep-02
Metcalf 2 hours
This is the first ride on this bike since Sid’s bachelor party.
Oct. 18, 2002
·         Re-lubed upper and lower linkage.
·         Re-lubed rear axle.
·         Cleaned air filter.
·         Repainted lower frame.
·         Replaced dust seals and spacers on rear axle.
·         Replaced spherical bearing dust seals on lower linkage.
·         Changed oil before Metcalf ride.
This is the first ride on this bike since Sid’s bachelor party.
Nov. 15, 2002
4 hour ride at Clear Creek
changed gear oil
Cleaned filter.
Dec. 06, 2003
Pulled bike out of storage shed.
Checked oil, looks good.
Cleaned air filter.
Tanked with fresh pre-mix (76 100 and oil) and started.
8-Dec-03
About 45 minute ride at Metcalf. Main jet: 180, Air Screw: 1.5turns.
Slight hesitation coming of idle.
Dec. 12, 2003
3 hours at Metcalf.
Temp: 55 degrees F. Main Jet: 180, Air Screw: 2.5 turns.
This Air Screw setting seems to work just fine.
Right fork tube pressure release valve is leaking.
Replaced fork pressure release valves, changed crankcase oil.
30-Jan-04
3 hours at Hollister
29-Mar-04
3 hours at Clear Creek
No jetting change from last trip to Hollister. Temp = 80
Cleaned air filter.
14-Jul-04
Bleed front and rear brakes. Used DOT 4 Bel Ray Brake fluid.
Will try VP Unleaded gas this trip out. Main Jet: 180
11-Jul-04
2 hours Clear Creek
No jetting change. Unleaded VP racing gas Main Jet: 180 Temp = 90+
Spark Plug inspection, inconclusive. Plug did not look like a rich condition existed, not enough riding time.
27-Jul-04
Changed oil, cleaned and replaced air filter.
7-Aug-04
Replaced rear tire. Dunlop D756 110/100-18
Current Update: July 29, 2003
Last Update: July 14, 2003
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