16
Assembly
.354 (Small Diameter)
Cap Nut
Fork Axle
• Place a .354 (small diameter) cap nut on a flat surface,
inside up.
• Fit the end of the fork axle into the cap nut.
• Tap the opposite end of the fork axle with a hammer to
secure the cap nut on the axle. Pull on the cap nut to
make sure it is securely assembled.
22
TM
Steering
Stop
Lower
Steering
Bushing
Headlight/Front Fork
Assembly
Tab
• Fit the tab on the steering stop into the curved slot in the
lower steering bushing
.
• Hold the steering stop in place.
• Slide the headlight/front fork assembly on the neck of
the vehicle frame and over the steering stop
.
2
1
Curved
Slot
23
21
Headlight
Assembly
Front Fork
• Position the headlight assembly “lens” side down on a
flat surface.
• Fit the front fork onto the back of the headlight assem-
bly as shown.
• Fit the two halves of the headlight assembly together.
• Insert three #8 x
3
/
4
" screws into the rear of the headlight
“housing”, as shown (20a).
• Turn the headlight assembly upright so the headlight “lens”
faces you. Insert two #8 x
3
/
4
" screws into the front of the
headlight “lens” (20b).
• Tighten all five screws using a Phillips screwdriver.
Do not over-tighten.
20a
20b
Headlight
Assembly -
Front Half
Headlight
Assembly -
Rear Half
“Lens”
DO NOT
INSERT
SCREW
HERE
DO NOT
INSERT
SCREW
HERE
2
1
• Insert four #8 x
3
/
4
" screws through the front fork and
into the headlight assembly.
• Tighten the screws with a Phillips screwdriver.
Do not over-tighten.
