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392 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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Cable shifter391 views
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391 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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391 viewsPush the power supply wires into the original headlight bulb connector.
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391 viewsInside of forward gear and planetary gear mating teeth.
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391 viewsThe new pin in the hole, ready for welding.
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390 viewsThe pin is missing. Looks melted...??? Without this pin set in the case halves the planetary ring rotates and doesn't allow the forward gear to rotate properly.
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388 viewsMy fingers are pointing to the two pins that fit into the two rubber grommets that are part of the upper triple tree (visible in the foreground).
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...after.388 views
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388 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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Reference: Rear gear box, front side.388 viewsFront side of rear gear box. Steel roll pin is 3/16" x 1-1/4". This is where the drive shaft fits.
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388 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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387 views
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Before...387 viewsYard stick shows 32" at bar-end mirror mount.
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387 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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387 views
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387 viewsTo make it a little easier getting both of the HID wires into the small space I put a single loop in the wire, as shown. Then stuff it in there with the red wire.
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386 viewsI used a 5/8" socket to support the bearing so I could drive out the push rod.
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385 views
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Day-time, parking lamp only385 viewsComparison of the two bulbs. On the left is the standard incandescent and on the right is the LED unit.
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