The Code Is More Like Guidelines, Than Actual Rules.

I used to think that the Manufacturer’s Service Manual was the bible of how you work on your motorcycle. How dare you deviate from it! But this is how I learned to work on motorcycles. It was 2010, I just got my first dirt bike, a used 2003 YZ250F. One year later, I sold that one and I bought a 2006 YZ450F. I was younger and single, with lots of free time. So I spent all of that free time riding my dirt bike on the weekends and working on it after work on the weekdays.

Four stroke Motocross style dirt bikes require a lot of maintenance to keep them running in tip top shape. The more you ride, the more maintenance you have to do. And I loved riding it, but I also loved working on it. Luckily it was a Yamaha. In my experience, Yamaha dirt bike manuals are the best ones out there. No fuzzy black and white pictures, all drawn images, and the instructions clear and thorough. This makes learning less intimidating.

Let me beat my chest for a bit, before I embarrass myself. Of the things that I’m good at, I’m probably the best at working on motorcycles. I’ve adjusted valves, replaced top ends, complete tear-down and rebuilt suspension. I’ve even installed new valve guides, sized them, then cut the valve seats to match the new guide. Many times I’ve had friends and family members bring me their motorcycle because they either didn’t know how to perform the needed service, or got stuck in the process. With that said, I don’t know everything and here is a clear example of an elementary process that I never learned. I recently learned that you should fill the oil filter with oil before installing it. None of the motorcycle manuals I have ever owned, never said anything about filling up the oil filter with oil. It’s amazing how quickly the “No Oil Pressure” LED or symbol goes out on the dash when you pre-fill the oil filter.

Now that I think about it, the Kawasaki Service Manual for my 2003 ZX6RR never says anything about burping the oil filter. I had to learn that one from a Google search. By burping, I mean you have to leave the oil filter slightly unscrewed so there is air gap between the oil filter’s O-Ring and the sealing surface on the engine. You need to start the engine, once oil starts coming out of this gap, quickly screw the oil filter on the rest of the way. And no, pre-filling the oil filter does not remedy the burping procedure.

Also, the Kawasaki Service Manual for my KX450 says you need to torque the oil drain bolt to 89 ft-lb! That would be a disaster, you’d probably have to split the cases to fix the threads on that mistake.

If I’m working on a motorcycle that I’ve never worked on before, I want the Manufacturer’s Service Manual, because it’s your best bet in knowing how to successfully work on your bike. But proceed with caution. You are going to need a little experience, before you can apply common sense. And don’t be afraid to edit your guidelines (manual). There’s lots of open space to make notes and to tell the manufacturer that they are wrong and you know a better way.