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444 viewsNow the bar-end mount is up two inches at 34" high.
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444 viewsAnother view of the same worn teeth.
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With film applied.444 viewsRunning light on.
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444 viewsPush in the power supply spade connectors into the headlight connector. As can be seen in the picture, I put the black wires together and the red wire with the white wire.
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443 viewsHere's what they look like. A simple and effective design. Here's where you can get 'em:
http://www.bhpbikeparts.co.uk/content/products/
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443 viewsI originally tapped the existing mounting holes in the resistors with 4M x .7 threads but I decided to add Nyloc nuts to insure nothing came loose. All fasteners I used are stainless steel.
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443 viewsRemoving the one-way retaining washer is a pain in the butt. Chances are very good that you could end up breaking the pin...not that it's a big deal if that happens, honestly. I did this on the left side to remove the turn signal electrical connector away from the rest of the harness, then pushed the retainer back on.
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442 viewsI used a 5/8" socket to support the bearing so I could drive out the push rod.
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442 viewsSince I wouldn't be using any of my original plates I used one as a lock to hold the clutch drum so I could remove the center retaining bolt.
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441 viewsThis is the outer-most friction plate and driven plate. The average thickness of the friction plates was ~2.8mm. They should be replaced if they are less than 3.2mm!
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441 viewsThe new clutch pack and stacking instructions. No idea what the bottom image is for, I just used the top part.
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441 viewsConnect the wires to the power plug. Now all the ignitor and ballast wires are attached so you can push them further into and down inside the headlight bucket. Now you can loop in the other zip-tie to secure the ballast, cutting notches in the hourglass brace like I did if you want. If you removed the high-beam bulb you can now put it back in, along with its wires.
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440 views"Tool tray" needs to be removed for tucking the wires in on the right side. There are six of the 4mm fasteners holding it down.
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439 viewsUse a Phillips screwdriver to remove the retaining screw at the bottom of the headlamp. No need to completely remove the screw, just until it becomes loose & wobbly.
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439 viewsAt the top pulley you mark the replacement belt perfectly with the mark on the old belt. You can now remove the vertical belt and quickly replace it with the new belt, followed by the horizontal belt. Adjust the belt tension and then go ride!
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439 viewsUse a drift to tap out the push rod.
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439 viewsSize comparison of the incandescent (left) bulb vs. the LED unit (right). Though the LED unit is taller it will still fit inside the signal housing with room to spare.
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439 viewsConnect the ignitor wires to the bulb. One thing I did to make this wiring install easier is to remove the weather seal that holds the 4 wires. Since everything is contained within the headlight bucket there's no need for the wiring seal. Carefully use a sharp blade, like a crescent X-acto blade, to cut the seal and remove the wiring.
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438 viewsHow it looks in the display box before unpacking.
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437 viewsAnd with mia ragazza herself.
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