Install rear fender using the two
attach bolts in the center of the frame. Install rear
fender brace tubes. Note
that the fork end of the brace tubes tubes attach to the frame.
bracket has the tail light attachment.
Place chain on engine
the brake and sprocket hubs on
the rear wheel. Align the rear wheel assembly with rear axle plates on
Place chain on wheel sprocket. Put rear axle through chain adjuster on
axle spacers, and rear wheel assembly. Note: The longer axle spacer
goes on the
brake side. Ensure correct chain tension by using chain adjusters on
Tighten axle nut*.
brake hub brace tube. Check
to make sure tire does not make contact with rear fender brace tube
Hub attach point should be at the 6 o'clock position.
Tighten upper triple
clamp on fork
tubes. Triple clamp should be flush with the top of the fork tubes.
Loosen lower triple clamp and slide down fork.
Place flat washer on steering bolt.
high temperature bearing
grease to tapered steering bearings. Place one bearing on steering bolt
above the washer and install the second on the top race on frame
tube. Slide steering
bolt up through steering
large bolt under upper triple clamp. Slide upper triple clamp down over
steering bolt. Install and tighten large cap nut
of upper triple clamp*. Tighten lower triple clamp* on fork tube.
Loosen springer clamp and
position midway between high and low travel. Retighten
onto fork tubes*.
front wheel by placing front
axle through lower rockers and wheel spacers. The shorter spacer goes
rotor side of the wheel. Tighten axle nut*.
fiber/metal washer on exhaust port and bolt exhaust to engine
head. Place rubber fender washer between exhaust mounting tang and
frame and attach bolt.
Install kick starter pedal on splined
shaft. Tighten both clamp bolt and set screw*.
Secure headlight to
Connect headlight wire to plug on frame.
handlebar risers on upper
triple clamp. Make sure that risers are aligned to fit the handlebar
tightening. Place handlebar on risers and
secure in place with riser caps*.
Remove plastic chock
pads on the brake caliper. Slide caliper onto rotor and Attach
brake caliper to mounting bracket. If caliper bolt holes do not align
with the bracket holes, slide springer clamp up or down. This will
reposition the brake rotor and allow the caliper bolt holes to align.
If needed the triple clamps can be loosened to rotate the fork tube to
align the caliper bracket with the rotor. Once the caliper is bolted to
the bracket, lower the springer clamp on
the fork until the brake caliper is close but not touching the outer
edge of the rotor. Retighten springer clamp and the triple clamp bolts*.
Unscrew the top of the
and remove slide. Warning: The slide return spring is under tension and
exit the vehicle. To remove the slide place your pinky finger inside
the top of
the carb down to the slide. Hold side pressure on the slide and pull
up. Feed the throttle cable through the carb
return spring. Secure the end of
the throttle cable to the slot on the slide. Place the slide into the
making sure that the beveled edge of the slide is towards the air
filter. Hand tighten the top of the
carb. If it is necessary to adjust the throttle housing on
the handlebar you must first loosen the housing set screw .
Be aware that the two
screws that hold the housing halves together are only to be snug tight
and do not fixate the housing on the bar. If these screws are
overtightened the threads may strip and this will not be covered under
forward control horns onto
brass bushings and position into forward foot peg mount on frame. Note
that the top of the control horn
convex. Slide threaded foot peg rod through
frame tube and place flat washers
against each control horn. Screw foot pegs onto threaded rod*. Do not
overtighten as this will fracture brass bushings. Check to
see that the control horns rotate freely. If not you may need to
dress the brass bushings with a file to give free clearance.
Remove rod end from left
horn and thread onto jockey shift pushrod. Reinstall
rod end onto control horn. Slide jockey shift
onto gearshift spline on engine and tighten clamp bolt*.
tail light on mounting bracket
on left rear fender mount tube and secure with bolt. Plug wires into
corresponding wires inside faux oil tank which can be accessed by
removing the left side cover.
Apply pipe sealant and Thread petcock onto gas tank
fitting. Make sure that the lever is to the right side of the tank.
Place gas tank onto frame
rubber washers under brackets. Install mounting
bolts. With the stainless steel
cover over the fuel line, push fuel line onto tank petcock and
gas cap onto filler neck.
Remove adjustment nut,
spring from rear brake rod. Make a slight bend 8” from the rear end and
the front on the rod. Reinstall spring. Put brake barrel through brake
wheel hub. Place rear brake rod through alignment bracket on frame and
barrel. Thread adjustment nut onto brake rod.
Note that the brake arm should be
at the position if properly
adjusted. If not, the brake arm can be
repositioned on the splined shaft.
rod end from right control
horn. Thread rod end onto brake rod. Reinstall rod
end onto control horn.
brake rod return spring
between frame tang and hole drilled through brake rod.
brake light actuator spring
to switch on the frame under the kick start pedal. Slide strait spring
through hole in brake rod end and bend back.
Connect red (positive)
and black (negative)
wires to battery. Secure battery with rubber blocks. replace battery
side cover and tighten leather straps. Note: electric start will not
function unless rear brake is depressed.
Check engine oil level. Use 20w50 motor oil.
Recheck tightness of all
bolts and nuts on bike. Be sure that the set screws on the side covers
of the electrical box are tight and have Loctite applied.
Inflate tires to 32 psi.