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475 viewsAll the bearings are roller bearings and they are held in with the grease. When cleaning the grease and wiping the bearings they will most likely fall out so work over a soft, plush towel to keep them from bouncing away. Pack the bearings and cage surfaces with fresh grease and slip any fallen bearings back in. You should see no gaps between the bearings. Pack more grease in when they're all in and roll them around with your finger to spread the fresh grease around. It will hold them in there.
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475 viewsPermatex 2A gasket silicone is what I smeared on the mating surfaces of the case half instead of using a gasket.
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474 viewsClutch pack removed. See all those teeth marks? Yeah, that's how a clutch basket SHOULDN'T look! Very worn out.
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474 viewsThe springs should be no less than 41mm. Mine were at 36mm!
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Side view, half and half474 viewsLower half with lightest tint applied, LED and top have no film on them.
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474 viewsThis shows the plug and orientation of the ballast. That plug is where the power comes in once everything has been installed. Notice the ignitor is outside of the headlight housing.
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473 views
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472 viewsMy li'l Trini girl in heaven.
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472 viewsWith the foam removed you can see the expanded metal mesh it rests on. The forward holes are above the mesh while the rear holes are below it.
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472 viewsHere's the VR (voltage regulator) information. This is what you need. I got mine for $3.15 at Norvac Electronics, Inc. You can also get it at Fry's. NTE1932, IC voltage regulator, positive 10-volts, 1-amp.
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472 viewsLeft side are the 'raw' bits that make up the mounts. On the right is the completed right mount.
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471 viewsApplying the finishing touches.
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471 views
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471 viewsTa-da!
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471 viewsInside of forward gear and planetary gear mating teeth.
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470 viewsTop removed exposing the foam sponge that traps the oil vapor.
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470 viewsRemoving the pillion backrest and grab handles is very easy. There are only three, 6mm bolts. One under the seat on each side (red arrow) and the other one is below the back rest mount, center-line of the seat. Be careful when lowering it due to all the wiring. I would also recommend covering the rear fender to protect both pieces from being scratched.
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470 viewsFirst zip-tie installed. I waited on the second one so I could move the ballast a little while working on the electrical cabling. This just helps get the ballast out of the way and keeps it from moving around too much. You can now install the HID bulb and secure it.
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469 views
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469 viewsClose-up of the left side of the breather.
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