4000 mile maintenance

[druggist]

So I am about to do the 4000 mile maintenance from the Hanes manual, but being in graduate school and working, I don't have a ton of time (only Sunday's to ride and do maintenance). Can someone give me an estimation of how long each part of the maintenance takes? Keep in mind that I'm a noob, so it will take longer.
Here is the list of things to do:

1. check the specific gravity of the battery electrolyte
2. tighten the cylinder head nuts and exhaust pipe bolts
3. check the valve clearances
4. check the spark plug gaps
5. check the fuel hoses and system components
6. change the engine oil and replace the oil filter
7. check and adjust the engine idle speed
8. check the operation of the clutch
9. check and adjust drive chain freeplay
10. check for drive chain wear and stretch
11. check the brake pads for wear
12. check the brakes for correct operation, and for fluid leakage
13. check the tyre and wheel condition, and the tyre tread depth
14. check the steering head bearing freeplay
15. check the tightness of all nuts and bolts

And I'm not sure if it is included in step 8, but I think I need to adjust the freeplay in the clutch, because when i release it, it doesn't begin to engage until the lever is almost completely open (basically, when releasing the clutch, the first 80% does nothing). If this is not included in step 8, how long would this take?

I would really appreciate estimations for each part, but if that is a hassle, at least let me know the total time estimation.

Thanks,

Druggist

[Big Rich]

Start to finish with no unforeseen problems? Probably looking at all day (at a relaxed pace).

I would break that list up into smaller sections that deal with each other and spread the load over a couple weekends. That way if you do run into a problem (need shims, snap an oil filter stud, etc) you won't be rushed to complete everything.

[adidasguy]

1. check the specific gravity of the battery electrolyte - check water and when new battery needed, get sealed or LiFe type and never have to do this again

2. tighten the cylinder head nuts and exhaust pipe bolts - do when head cover off and doing valves
3. check the valve clearances - these 1-3 hours as you have to remove the tank and stuff to get to the valves and head bolts. If first time, allow all day (Bike must be cold to do #2 and #3)

4. check the spark plug gaps - not really needed much these days as plugs came pre-gapped

5. check the fuel hoses and system components - 5 minutes and do when tank off

6. change the engine oil and replace the oil filter - 1/2 hour. Slightly warm bike helps old oil flow out faster.

7. check and adjust the engine idle speed - you probably do this regularly. 1 minute anyway

8. check the operation of the clutch - 5 minutes

9. check and adjust drive chain freeplay - 10 minutes and oil the chain
10. check for drive chain wear and stretch - do with above item

11. check the brake pads for wear - 5 minutes. Longer if you need new pads or change fluid
12. check the brakes for correct operation, and for fluid leakage

13. check the tyre and wheel condition, and the tyre tread depth - you should do this regularly but 1 minute anyway

14. check the steering head bearing freeplay - you'd probably have noticed if too loose but 5 minutes tops

15. check the tightness of all nuts and bolts - 1/2 hour

** Check forks for leaking seals
** Check all lights and indicators and brake switches
** Check headlight alignment
**Wash bike and clean all the greasy crap off of it - 2 hours to detail your bike.

Remember in many areas bike shops are closed on Sunday and Monday. Be sure you have all parts for a task before taking things apart. If you bought extra parts? You'll use them next time.

[druggist]

Thanks, I really appreciate the help from both of you.
I guess I will try to start with the valve clearances, since that's the hardest and longest part (I know, that's what she said...), then I'll do the things that need the tank to be off right then.

druggist