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625 views...and screw the cap back on. This will help keep the DOT-4 fluid from flowing out when you remove the banjo fitting from the stock unit.
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625 viewsI chased the clamp bolt holes with a tap to expose the bare metal. I opted to not use the supplied lock washers because I don't like the idea of them digging into the paint and exposing the metal to air and moisture (rust). So ALL fasteners have blue Loctite on them to hold them in place. I used a flat washer under every bolt head and under every nut.
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Back side624 viewsChin bar in rear position.
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623 viewsThe OEM setup. The red line is the stock power cable that comes from the battery to the relay, down the right side of the engine, and under the engine to the starter.
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622 viewsThere are spacers in the gasket and they may come out with the bolt. No big deal, simply pull the spacer off the bolt and put it back into the gasket.
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...after (hi-rise clip-ons).622 views
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618 viewsWill even work for my son's bicycle :-)
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Before (stock clip-ons)...617 views
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616 views
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607 viewsChin bar in back position.
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606 views
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605 viewsClose-up of the OEM cable (red line) as it wraps around the front of the clutch and then to the starter post on the starter.
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595 viewsAll connected. Use the Bentley wiring diagram to assist but this is basically how it's wired. Remember, you're simply replacing the vibrator with the VR and using a resistor pack in-line with the fuel gauge sender to bring the voltage down to a reasonable level.
+12V (black wire from gauge cluster) -> VR -> gauge -> resistor pack -> tank sender (brown w/black stripe wire)
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595 viewsRemove the headlight and place on a thick towel. The low-beam is at the top of the headlight, which is the top of this picture. This shows the back removed and the bulb area exposed -- there are 7 screws that hold the back on. The greyish-silver bolt at the 11 o'clock position on the outside edge is the headlight vertical adjustment. To get more operating space inside the housing I rotated mine anti-clockwise 6 turns. Make sure you mark the bolt with a spot on the housing so you know where to return it when everything is all installed.
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Skully grips by Driven592 viewsBefore. Stock grips.
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586 viewsLooking forward, this is the point where the main heater duct connects to the forward 'Y' where some heat can be diverted to the interior floor vent that is between the driver/passenger seats that points into the center of the Bus. Here the flap is closed so all heated air goes to the front of the Bus.
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586 viewsWhat it looks like under the dash when put back together. The resistors aren't touching anything and there's no tension on them.
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580 viewsThe four bolts are removed and the cover is on the ground (it's resting on a foam Frisbee). Notice that the bolts are different lengths so make sure you put them back in the same holes. You can also see the clutch dust in the cover and on the exhaust pipe.
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578 viewsI put a scrap piece of insulation (that I removed from the corner) under the split-loom to fully cover the duct.
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575 viewsHere's both oil lines in the bracket.
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