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To grease bearings, remove adjusting nut and remove the steering stem
from the chassis from the bottom. Clean the bearings thoroughly and inspect
for missing bearings, damage to the bearing cage or ball bearings. See photo
III-67. Clean and inspect the ball races on the chassis, the steering stem, and
on the steering stem adjusting nut assembly. Replace any worn or damaged
parts. Using a high quality waterproof grease, thoroughly pack the upper and
lower bearings with grease. Also coat both upper and lower races with
grease. Place the lower bearing on the race on the bottom of the steering
stem, then insert the steering stem into the steering tube from the bottom.
Insert the upper bearing into the upper race and thread the steering stem
adjusting nut and race assembly onto the top of the steering stem. Snug
adjusting nut onto the upper bearing. Tighten the steering adjusting nut just
enough to eliminate any play or slop in the steering. The stem should not be
loose, but should take only minimal effort to turn. Fit the upper fork clamp
over the top of the steering stem and lightly tighten the steering stem nut.
Insert the forks into the fork clamps and tighten the lower fork clamp only.
Tighten the steering stem nut to 18 ft/lbs. Tighten the upper fork clamps now
to 11 ft/lbs. Replace the bars and torque mounting bolts to 18 ft/lbs. Install
bar pad, front fender, wheel and number plate. Recheck the steering for play
and binding from side to side.
Grip replacement
- The rubber grips will become damaged and worn over
time. When the bike falls, the ground will tend to cut the grips and push
them into the handlebar. The throttle tube can also crack over time with
crashes and will need to be replaced.
To remove the grips, slit them from end to end with a razor blade
and peel them off. Remove as much of the old glue as possible. Now
is a good time to seal the handlebar tube, so dirt doesn’t get into the
left side of the bar and work its way to the right side and the throttle
tube. Squirt a little expanding foam or a glob of silicone into the left
side of the bar and allow to harden.
To install the grips, it is best to use grip cement. Follow the direc-
tions on the glue for best results. Make sure the glue does not get
onto the end of the throttle tube that goes into the housing. Remove
any excess right away. Allow the glue to dry overnight before riding.
However, if you need to ride the bike right away, install them dry or
wrap a layer of friction tape around bars first. Safety wire grips on
both ends and in the middle. Twist the safety wire until it bites into
the grip. Cut the end of the wire short, about
1
⁄
8
˝, then bend the end of
the wire into the grip so there is no sharp end exposed. Safety wire
pliers work well, but a pair of locking pliers will do the job in a
pinch.
20. Electrical system
Spark plug -
Check spark plug for proper coloration and fouling.
Replace as needed. Adjust jetting and make repairs as needed to pro-
duce proper plug coloration. Use NGK plug R4118S-8 or B9EV as
standard plug. Gap at .024” using a wire type gapping tool. A resister plug is also acceptable but not required.
Check spark plug for color and condition. As long as the spark plug is the proper heat range, the coloration of the plug after a full
throttle test will provide clues as to main jet calibration. If the plug is dark and oily, the main jet is too rich. If the plug is white or
light colored, the main jet is too lean (a new spark plug must be run for 10-15 minutes for this test to be valid). When installing
spark plug, torque to 20 ft/lbs. If torque wrench is not available, tighten by hand, then another
1
⁄
2
to
2
⁄
3
of a turn.
Plug reading
- Reading the spark plug will yield valuable information about the accuracy of the jetting. This test will only work if
the plug is the proper heat range. A plug that is too hot will overheat and always seem to indicate a lean condition. A spark plug that
is too cold will always foul and seem to indicate an overly rich condition.
To take a plug reading, make sure the plug has had at least 15 minutes of running time if new. Warm the bike to operating temper-
ature. In a safe open area, accelerate with the gas wide open as long as possible, then hit the kill switch to shut off the motor and
coast to a stop. Hit the kill switch while the throttle is still wide open.
Upper steering bearing and race.
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Steering stem adjusting nut.
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