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434 viewsDetail of the top triple tree with stock clip-ons.
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434 viewsUpper triple tree removed. Use a 6mm Allen wrench to loosen all clamping bolts. Alternately tap the bottom of the clip-ons to walk the triple tree and clip-ons up. I used a block of wood positioned under the clip-on and tapped it with a rubber mallet -- just in case I missed the wood!
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434 views
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Side view, both lights covered434 viewsTop and bottom lights covered in lightest tint, LED not covered.
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433 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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432 viewsAnother view of the same worn teeth.
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431 viewsThe new clutch pack and stacking instructions. No idea what the bottom image is for, I just used the top part.
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430 views
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430 viewsIn order to remove the upper triple-tree the headlight needs to be removed and then the U-shaped ladder part that the headlight attaches to is then removed. Remove the two nuts at the bottom of the ladder then lift it up. Also, disconnect the headlight connector and put the headlight out of the way.
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430 viewsI placed a friction plate back in to measure the gap. I had to use an Allen wrench: 2.5mm. Not good. Max gap is supposed to be no more than 0.6mm!
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430 viewsThis is the outer-most friction plate and driven plate. The average thickness of the friction plates was ~2.8mm. They should be replaced if they are less than 3.2mm!
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430 viewsThe springs should be no less than 41mm. Mine were at 36mm!
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430 viewsFor safety I wrapped each connector in electrical tape and then wrapped them together as well.
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427 viewsHere's how the clutch basket looked. Those streaks are LOTS of thread locker applied at the factory. It leaked out the back side as well. After removing the eight retaining bolts I had to use a drift and tap a couple of the ears on the basket to gently break it free.
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427 viewsRemoving the spacer.
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427 viewsThe resistor mounts fit in the groove of the rear rubber seat rests.
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Day-time, parking lamp only426 viewsComparison of the two bulbs. On the left is the standard incandescent and on the right is the LED unit.
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425 viewsI used a 5/8" socket to support the bearing so I could drive out the push rod.
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425 viewsMounted and behind my Rizoma vented clutch cover.
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424 viewsConnect the wires to the power plug. Now all the ignitor and ballast wires are attached so you can push them further into and down inside the headlight bucket. Now you can loop in the other zip-tie to secure the ballast, cutting notches in the hourglass brace like I did if you want. If you removed the high-beam bulb you can now put it back in, along with its wires.
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