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Repacking silencer -
To service silencer, remove right side panel/number plate.
Remove bolt and clamp securing silencer to frame using a 6mm allen wrench.
Twist and pull silencer off pipe. Remove three bolts at front of muffler using a
4mm allen wrench. Hold rear section of silencer with one hand and pull outer
body of silencer off with other hand. Remove all remnants of silencer packing
from both sections. If holes in inner tube are partially or fully clogged, use a drill
bit of the proper size to remove the deposits from all the holes. Use a wire brush
on the outside to help loosen deposits. Purchase fiberglass packing made for
motorcycle silencers. If necessary, cut packing to the width of the silencer inner
tube by about two feet long. Starting at one end, roll the packing material around
the silencer inner tube, tucking the material into the endcap as needed. Wrap
material snugly, but not so tight as to compress the material more than a little bit.
If the packing will not fit into the outer body, unroll the packing a few inches
and trim off material until the outer body will fit snugly. Slide the outer body most of the way on, then seal the endcap with a light
coat of silicone sealant to help prevent oil from dripping. Slide the outer body over the endcap, align the three holes and insert and
tighten the three bolts. If oil drips out of silencer, a leaner main jet may be indicated. See section III-18 for testing procedure.
11. Cables - adjustment & lubrication
Check throttle and brake cables frequently for binding or damage. Check for frayed ends or broken strands. Make sure cables have
proper amount of freeplay. Cables can be lubricated with a special tool, available at most motorcycle stores. Replace cables often,
lubrication will not fix a damaged or worn cable. Lubricating a cable will also attract dust, so inspect lubricated cables often.
12. Plastic care and cleaning
Cleaning bike frequently will keep motorcycle cooler and reduce weight. Mud can substantially increase weight of motorcycle. A
clean bike is easier to inspect and service. However, be very cautious if using a pressure washer! The extremely high pressure water
can cause considerable damage to wheel bearings, steering bearings, brake calipers, shock and fork seals, throttle grip, suspension
bearings & bushings, carburetor, air cleaner and many other areas. Do not spray these areas directly, rather, work carefully around
them to remove dirt but not force dirt or water into the bearing and seals of the motorcycle. At end of day, remove alternator cover
and wipe any moisture out with a clean rag. The heating and cooling of the electrical system tends to cause moisture to condense
inside the cover. If racing in mud, spray silicone or cooking spray heavily inside fenders and on number plates to help repel mud.
Also spray a light coat on number plates to help keep numbers visible. Do not use any abrasive cleaners on plastic. Soft Scrub
®
cleanser seems to work well for cleaning dingy white plastic. Simple Green
®
is excellent for overall bike cleaning, and is non-toxic
and biodegradable as well. It also works well for removing stains from riding gear. A light coat of WD40
®
will keep the bike looking
shiny and new. A product called Plastic Renew
®
also does a good job of making plastic and decals shiny and repairing minor scuffs.
13. Footpegs
Check footpegs often for proper operation. Make sure they pivot freely and return smartly to level position when released. Bend
spring for more tension or replace to maintain proper operation. Check pegs to make sure they are level, replace if they are bent.
Points of teeth can be filed to restore them to their original condition, but for safety’s sake do not make them overly sharp. Sharp
teeth will also increase boot wear.
14. Vent hoses - carburetor, coolant & transmission
Make sure vent hoses are properly routed and not kinked or clogged at the ends. The carburetor vent hoses tend to get clogged at
the ends, which can prevent the carburetor from working properly. The hoses should run between the end of the transmission cases
Roll new packing material around inner core.
Inserting inner tube and packing into outer body.
insert packing
into endcap
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