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476 viewsThis shows the plug and orientation of the ballast. That plug is where the power comes in once everything has been installed. Notice the ignitor is outside of the headlight housing.
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476 viewsAll the bearings are roller bearings and they are held in with the grease. When cleaning the grease and wiping the bearings they will most likely fall out so work over a soft, plush towel to keep them from bouncing away. Pack the bearings and cage surfaces with fresh grease and slip any fallen bearings back in. You should see no gaps between the bearings. Pack more grease in when they're all in and roll them around with your finger to spread the fresh grease around. It will hold them in there.
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475 viewsHome-made gasket made from 1/32" rubberized gasket material from the FLAPS.
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475 viewsClutch pack removed. See all those teeth marks? Yeah, that's how a clutch basket SHOULDN'T look! Very worn out.
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475 viewsThe springs should be no less than 41mm. Mine were at 36mm!
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475 viewsPermatex 2A gasket silicone is what I smeared on the mating surfaces of the case half instead of using a gasket.
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474 views
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474 viewsLeft side are the 'raw' bits that make up the mounts. On the right is the completed right mount.
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473 viewsMy li'l Trini girl in heaven.
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473 viewsWith the foam removed you can see the expanded metal mesh it rests on. The forward holes are above the mesh while the rear holes are below it.
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473 viewsHere's the VR (voltage regulator) information. This is what you need. I got mine for $3.15 at Norvac Electronics, Inc. You can also get it at Fry's. NTE1932, IC voltage regulator, positive 10-volts, 1-amp.
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473 viewsFirst zip-tie installed. I waited on the second one so I could move the ballast a little while working on the electrical cabling. This just helps get the ballast out of the way and keeps it from moving around too much. You can now install the HID bulb and secure it.
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473 viewsInside of forward gear and planetary gear mating teeth.
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472 viewsApplying the finishing touches.
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472 viewsTa-da!
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472 viewsRemoving the pillion backrest and grab handles is very easy. There are only three, 6mm bolts. One under the seat on each side (red arrow) and the other one is below the back rest mount, center-line of the seat. Be careful when lowering it due to all the wiring. I would also recommend covering the rear fender to protect both pieces from being scratched.
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471 viewsUse a #1 Phillips screwdriver to remove the clear lens retaining screw.
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470 views
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470 viewsTop removed exposing the foam sponge that traps the oil vapor.
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