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I
Begin by cutting the plastic zip tie straps securing the front and rear
calipers to their mounting brackets.
Install front fender using 4 phillips head screws M6x16 and 4 washers
M6x18x1.
Install the front wheel next. Spread brake pads enough to accept rotor,
then align front wheel with axle holes in forks. Insert front axle from
right side of bike, through front wheel and into the left fork. Using a
5
⁄
16
”
or 8mm allen wrench, turn the axle until it is fully threaded into the left
fork, then torque to 50 Nm. Next compress the forks several times to
properly align the forks on axle. Install and tighten axle pinch bolt using a
6mm allen wrench to 25 Nm.
Install handlebar using 2 U-shaped bar clamps with 4 M8x30 socket
head bolts using 6mm allen wrench. Make sure gaps are even from front
to rear of bar clamps. Tighten bolts to 25 Nm. Install bar clamp pad using
2 zip ties provided. Install kill switch on left side of handlebar near grip
pointing up using 2 piece clamp assembly in hardware package.
Route cables as outlined in section II-4. (See page 8)
Adjust front brake lever (bar mounted rear brake lever also, if so
equipped) using adjuster on lever so that free play is from 4 to 5mm,
measured at gap between lever and and cable holder - See photo III-2.
Check wheels for free rotation and proper braking when levers are
applied.
Remove 2 screws from top of throttle housing and remove cover.
Install end of cable into top hole in throttle tube. Install throttle cover
making sure cable is in groove. Twist throttle repeatedly to check for any
binding or failure to return to rest position when released. Fix sticking or
sluggish throttles. Do not lube throttle grip assembly but remove and
clean as needed. Use a small piece of duct tape to secure cable to adjuster
to prevent setting from changing or cable from pulling out. Push cable
boot fully onto throttle housing, using a small zip tie on the end of the boot will help prevent dirt from entering. These tips also
apply to the carburetor end of the cable.
Install front number plate by inserting 3 fingers into holes in front fender, then insert phillips M5x30 screw using metric spacer
5.5 x 12 x 20. Spread the grey plastic front brake cable guide over cable, push into hole in front number plate.
Install footpegs using SCS M8x40, a M8 lock nut, and footpeg spring. See photo I-3. If necessary, bend straight end of spring
down with a pair of pliers to tension footpegs more. To make spring easier to install, use a pair of pliers or a vise to compress spring,
then hold in position using a small zip-tie. Install spring and then cut zip-tie to release.
Inflate tires to 18 psi.
Fill radiator with approximately 27oz. (with dual radiators) of
Engine Ice
®
antifreeze (ready to use). See section III-4. Fill trans-
mission through vent hole or level checking screw hole with 300
cc (10 oz.) Maxima brand MTL 75 gear lube for best results.
Remove checking screw and fill slowly in case some oil is already
in transmission. Do not overfill. See procedure in section III-6.
Remove rubber cap from crankcase vent fitting and push vent
tube onto fitting. (See photo I-4)
If kickstarter hits expansion pipe when folding in, remove pinch
bolt using a 5mm allen wrench and remove kickstarter. Insert
screwdriver blade into slot to loosen kickstarter on shaft if neces-
sary. Reposition kickstarter rearward 2-3 splines and re-install.
Torque pinch bolt to 10 Nm.
Apply the decals last (if necessary). Remove the fuel tank with
shrouds attached before applying the decals to them. Try to apply
the decals in a warm, clean, well lit area and at least 24 hours
before the bike is to be ridden.
It is very important to properly prepare your bike’s plastic for
application of pressure sensitive decals. The plastic should be
cleaned with conventional soap and water, and any scratched areas
should be lightly sanded to make them smooth. The smoother the
surface the better the adhesion. Before you peel back the backing
on the decal, fit it in place and line it up properly. Tape it in position
All nuts, bolts and small parts are in a bag inside box.
Footpeg installation - left side shown.
kill switch
clamp
front number
plate screw &
spacer
front axle
pinch bolt
front brake
cable clamp
front fender
nuts & washers
front
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