| Install rear fender using the two attach bolts in the center of the frame.
Install rear fender brace tubes.
Note that the fork end of the brace tubes tubes attach to the frame. The left side bracket has the tail light attachment.
Place chain on engine drive sprocket.
(This is for Rear Brake on 2008)
Place the brake and sprocket hubs on the rear wheel.
Align the rear wheel assembly with rear axle plates on frame.
Place chain on wheel sprocket.
Put rear axle through chain adjuster on frame, axle spacers, and
rear wheel assembly.
Note: The longer axle spacer goes on the brake side.
Ensure correct chain tension by using chain adjusters on frame. Tighten axle nut*.
Install brake hub brace tube. Check to make sure tire does not make contact with rear fender brace tube bolts. Hub attach point should be at the 6 o'clock position.
Install chain guard on engine.
(This is for Rear Brake on 2009)
Forward control rear brake installation
First you will need to install your rear brake master cylinder, and reservoir as you can see in these pictures. The master cylinder mounts near the battery box. You can mount it on top or underneath. If you mount it from the bottom you will not have to bend your brake rod, but you may sacrifice frame clearance this way. It is a matter of preference.
The reservoir can be mounted here
I used s small spacer and nut and bolt to achieve proper clearance and to keep it in place as shown here.
After installing the master cylinder you need to install the brake rod and springs correct location is illustrated in the next 2 pictures.
The rear spring goes through the rear brake light actuator, it has a small hole in it for the spring to go through. When doing this, make sure the spring is not to loose or to tight, or it will not engage the brake light correctly.
Installing the rear tire and rear brake I found this to be one of the most difficult tasks of assembly and believe it was much easier to do with an extra person.
First place your brake caliper in the correct place on the frame and slide your axle in far enough to hold it in place, then put your spacer on the end of the axle, just covering the threads. While putting the tire in place than pushing the axle through the wheel hub while leaving enough space to put the chain side spacer in place. I used a small pry bar wrapped in cloth to pull open the frame to get the space on this side in place. Place the axle lock nut on the axle but do not tighten.
You do not need to remove axle adjusters to assemble, this picture is simply for illustration purposes to show the correct location of the rear assembly.
If caliper alignment is incorrect you may need to use washers or spacers to correct the alignment as pictured here in the caliper bracket. Four 10mm lock washers were used to get proper caliper alignment here, two on each side of the caliper mounting bracket, along with longer bolts.
Tighten upper triple clamp on fork tubes.
Triple clamp should be flush with the top of the fork tubes.
Loosen lower triple clamp and slide down fork. Place flat washer on steering bolt.
Apply high temperature bearing grease to tapered steering bearings. Place one bearing on steering bolt above the washer and install the second on the top race on frame steering tube. Slide steering bolt up through steering tube.
Hand tighten threaded washer on large bolt under upper triple clamp. Slide upper triple clamp down over steering bolt. Install and tighten large cap nut on top of upper triple clamp*. Tighten lower triple clamp* on fork tube.
Loosen springer clamp and position midway between high and low travel. Retighten clamp onto fork tubes*.
Install front wheel by placing front axle through lower rockers and wheel spacers. The shorter spacer goes on the rotor side of the wheel. Tighten axle nut*.
Place fiber/metal washer on exhaust port and bolt exhaust to engine head. Place rubber fender washer between exhaust mounting tang and frame and attach bolt. Install kick starter pedal on splined shaft. Tighten both clamp bolt and set screw*. Secure headlight to springer clamp*. Connect headlight wire to plug on frame. Install handlebar risers on upper triple clamp.
Make sure that risers are aligned to fit the handlebar before tightening. Place handlebar on risers and secure in place with riser caps*.
Remove plastic chock between the pads on the brake caliper. Slide caliper onto rotor and Attach front brake caliper to mounting bracket. If caliper bolt holes do not align with the bracket holes, slide springer clamp up or down. This will reposition the brake rotor and allow the caliper bolt holes to align. If needed the triple clamps can be loosened to rotate the fork tube to align the caliper bracket with the rotor. Once the caliper is bolted to the bracket, lower the springer clamp on the fork until the brake caliper is close but not touching the outer edge of the rotor. Retighten springer clamp and the triple clamp bolts*.
Unscrew the top of the carburetor and remove slide. Warning: The slide return spring is under tension and may exit the vehicle. To remove the slide place your pinky finger inside the top of the carb down to the slide. Hold side pressure on the slide and pull up. Feed the throttle cable through the carb top and return spring.
Secure the end of the throttle cable to the slot on the slide. Place the slide into the carb making sure that the beveled edge of the slide is
towards the air filter. Hand tighten the top of the carb. If it is necessary to adjust the throttle housing on the handlebar you must first loosen the housing set screw . Be aware that the two screws that hold the housing halves together are only to be snug tight and do not fixate the housing on the bar. If these screws are overtightened the threads may strip and this will not be covered under the warranty.
Place forward control horns onto forward foot peg mount on frame.
Note that the top of the control horn is convex. Slide threaded foot peg rod through frame tube and place flat washers against each control horn. Screw foot pegs onto threaded rod*. Do not over tighten as this will fracture brass bushings. Check to see that the control horns rotate freely. Check to see that the control horns rotate freely. If not you may need to dress the brass bushings with a file to give free clearance.
2009 125cc Shifter Change (picture below for reference)
Remove rod end from left control horn and thread onto jockey shift push rod.
Reinstall rod end onto control horn. Slide jockey shift onto gearshift spline on engine and tighten clamp bolt*.
Place tail light on mounting bracket on left rear fender mount tube and secure with bolt. Plug wires into corresponding wires inside faux oil tank which can be accessed by removing the left side cover.
Apply pipe sealant and Thread petcock onto gas tank fitting. Make sure that the lever is to the right side of the tank.
Place gas tank onto frame and place rubber washers under brackets. Install mounting bolts. With the stainless steel cover over the fuel line, push fuel line onto tank petcock and carburetor. Thread gas cap onto filler neck.
Remove adjustment nut, barrel and spring from rear brake rod. Make a slight bend 8" from the rear end and 4" from the front on the rod. Reinstall spring. Put brake barrel through brake arm on wheel hub. Place rear brake rod through alignment bracket on frame and brake barrel. Thread adjustment nut onto brake rod. Note that the brake arm should be at the 7 O'clock position if properly adjusted. If not, the brake arm can be repositioned on the splined shaft.
(For 2008)
Remove rod end from right control horn. Thread rod end onto brake rod.
Reinstall rod end onto control horn.
Install brake rod return spring between frame tang and hole drilled through brake rod.
Install brake light actuator spring to switch on the frame under the kick start pedal. Slide strait spring end through hole in brake rod end and bend back.
Install rear view mirror.
Connect left side switch to wires on handlebar.
Connect right side switch to wires on handlebar.
Connect red (positive) and black (negative) wires to battery. Secure battery with rubber blocks. replace battery box side cover and tighten leather straps. Note: electric start will not function unless rear brake is depressed. Check engine oil level. Use 20w50 motor oil.
Don't Forget the oil
Apply Loctite thread lock on threads.
Brake Bleeding Instructions (Click Here)
NEW VIDEO FOR ADDING SPEEDOMETER |
