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Set front wheel of motorcycle in a vice, set
jack under the motorcycle and raise the jack to take the weight
off of the rear wheel. Remove upper and lower belt guards.
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Loosen axle adjusters on both sides. Remove axle
from wheel and swing arm. Slide the belt off of the pulley.
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Raise the jack high enough to remove the rear
wheel.
Remove front pulley cover.
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Remove the shocks from the motorcycle.
Remove the allen bolt that holds the rear brake master cylinder
reservoir, let the reservoir hang out of the way. Remove swing arm
pivot bolt on both sides. Remove swing arm.
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With swing arm and rear wheel removed, have a
friend help set a wheel and tire on the brake side of the rear
end.
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Set the rear end on the wheel that was previously
installed.
Remove the five bolts to the spokes, Note the green tape on the
star plates, this will help align the star plates back up. Remove
axle, axle housing and star plate as a unit. Install your pulley
on the differential housing. Torque the pulley bolts 55 to 65 ft.
lbs. Install belt over pulley as shown, the belt should be inside
of all spokes except the one that is marked with the green tape.
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Remove spoke that is marked with the green tape.
Install spacer on spigot of the differential housing. Install
axle, axle housing and star plate as a unit, Line up points of the
star plate with the green tape. Install bolts through star plate
to the spokes. ######################################################
Install axle adjuster bolts in to nut on the
swing arm. Install swing arm to rear end. Have a friend
help hold the swing arm. Install spoke previously removed as shown.
Do not tighten the bolts that mount the swing arm to the rear end.
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Install other wheel and tire on the axle.
Roll the rear end and position it behind the bike.
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Roll the rear end and swing arm under the bike.
Install Swing arm pivot bolts on both sides.
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Slide belt over front pulley, Torque swing arm
pivot bolt 60 to 70 ft. lbs. Install fenders on the sport fender
brackets. Remove top two star plate bolts, on one side at a time, install fender and
bracket on the rear end. Apply blue loctite, install top two star
plate bolts. Install lower mounting bolts and lock nuts on fender
bracket. Install fender and fender bracket on other side as
previously described. Torque lower fender bracket bolts and nuts
to 70 ft. lbs.
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Remove other star plate bolts one at a time
apply blue loctite and hold adjustable wrench on flat area of
spoke to torque bolts to 70 ft. lbs.
Do not torque front spoke.
Install shocks with longer bolts and spacers provided.
Torque shock bolts 45 to 50 ft. lbs
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Adjust belt tension to factory specs.
Tighten jam nut on adjuster bolts and torque the four rear end
mounting bolts to 70 ft. lbs.
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Install front pulley cover. Install the allen
bolt that holds the rear brake master cylinder reservoir, hook up
stock brake line, bleed rear brake, tighten lug nuts on rear
wheels torque 78 to 85 ft. lbs. and go for a ride. Re-torque
lug nuts after 25 miles or 100 mile maximum.
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