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452 viewsThe new pin in the hole, ready for welding.
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...after.451 views
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LED dual-element array (alternating white and amber LEDs).451 viewsCut the other end to the desired length or to simply remove the other wires. Use some heat-shrink at the end to seal it from the elements. I left a little over-hang and then bent the heat-shrink back on itself, then gently clamped with some needle-nose pliers.
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451 viewsWith the horizontal (front) cylinder belt removed I lined up my replacement belt for the vertical cylinder and marked it.
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451 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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451 viewsBearing grease (red) applied on the planetary teeth for mating to the rearward gear. I followed the instructions for the "new" teeth so I hope this is okay for the "old" teeth. I think it should be.
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450 viewsThe complete assembly and all lubed up.
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450 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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450 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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450 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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449 viewsFlap fully open, allowing some of the heated air to divert into the center of the Bus for the rear passengers.
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Turn signal switch449 viewsAll apart. Use white lithium on the left part of the switch, where the ball bearing rubs against the left wall. Use dielectric grease everywhere else.
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449 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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449 viewsWhile I was "in there" I decided to change out the O-rings at the other end of the push rod.
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449 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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449 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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449 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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