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| 21 | Complete with the gas tank, lift up and remove the rear triangle assembly. |
| 22 | Remove the skid plate from under the motor. The skid plate is secured with three bolts (Torx 30) |
| 23 | Remove the foot peg mounts. There are three bolts (Torx 40) holding each foot peg bracket to the frame. Remove the three bolts and the bracket along with the foot pegs. On the left side also remove the small exhaust guard plate. |
| 24 | Disconnect the two (1) electrical connectors, one for the oxygen sensor and the other for the kickstand switch. The bolt (2) at the rear of the lower frame member should be removed. (13mm wrench) The lower of the two motor mount bolts (3) should also be removed. (8mm hex) |
| 25 | Loosen the crankcase breather hose (4) by slightly bending the tab on the frame. Next remove the M10 bolt (5) that goes through the motor. (8mm hex) Last remove the two upper bolts connecting the mount to the frame.(13mm wrench) Hold on to the motor mount as you remove the top bolt. The bolt from (5) will be reused. |
| 26 | Disconnect the shift lever. Remove the bolt (5mm hex) and pull the shifter off. |
| 27 | Remove the head pipe. The two dome nuts connecting the pipe to the cylinder head must be removed. Save these. Also save the thin metal gasket from the end of the pipe. |
| 28 | Remove the oxygen sensor from the pipe. |
| 29 | Installing the new left side lower frame member. Secure the rear of the frame member to the frame using a new 8mmX25mm (6mm hex) from the inside. Do not completely tighten yet. |
| 30 | Attach the right side frame member using an 8mmX16mm (6mm hex) and a washer from the outside. Do not tighten. NOTE: Both lower frame members are mounted to the inside of the frame as seen in the photos. |
| 31 | Install the modified motor mount.
The motor mount installs using the original bolt (1), washers and lock nut from fig25. (5) and a new M10x125 Allen head bolt (2), washers and locknut. The two upper bolts of the mount are reused for now and will be replaced later with the installation of the tank mounts. At the bottom the new lower frame members are connected. The rear connections of the lower frame members can now be tightened to 15ft/lbs and the two M10 bolts of the motor mount can now be tightened to 30ft/lbs.
TIP: A small coating of grease can be applied to the lower frame members where they connect to the motor mount (2) to protect the coating. |
| 32 | Disconnect the brake pedal.
With a small screwdriver disconnect the clip that connects the actuator rod to the brake pedal. Now remove the screw (torx40) and pull outward on the brake pedal to remove. Save the bolt, washer and the bushing from inside the brake pedal. |
| 33 | Reposition the brake pedal spring into it's proper spot. |
| 34 | Install the new brake pedal:
Place the bushing into the new pedal, with the original screw install the new pedal. Make sure the lever on the brake switch is positioned above the brake pedal. The bolt can now be tightened to 15ft/lbs. Reconnect the rod from the master cylinder using the original clip. The shifter can now be installed on the left side. (5mm Allen key) |
| 35 | Remove the original foot pegs from the mounts.
Remove the cotter pin and washer then push the pin out of the mount. The pins, spacers, springs, and washers are reused. Disassemble both the right and left foot pegs. |
| 36 | The new foot pegs are now installed into the new foot peg mounts using the original hardware we just removed. Place the spacer and spring in the center of the foot peg, now place the peg into the mount with the bent end of the spring into the hole in the mount. Hold the foot peg in place and install the pin. Place the washer on the bottom and install a new cotter pin. |
| 37 | Install the new foot peg assemblies.
On the right, install the foot peg mount with three M8x20 button head bolts and the original washers. (5mm Allen key). On the left the upper and rearmost bolts are installed with M8x20 button head bolts and the original washers, the forward bolt is an M8x30 countersunk. Do not tighten the foot pegs yet, as we will need to install the skid plate at a later time. |
| 38 | Remove the sprocket cover from the motor. (torx30) Also remove the chain guard from the rear swing arm. With a chain tool, separate the chain and remove. Place the motorcycle up on a center stand. Disconnect the rear wheel, Remove the axle nut (24mm socket) while holding the axle (19mm wrench), now remove the axle and remove the rear wheel. |
| 39 | Remove the rear shock adjuster.
(1) Remove the bolt, nut, and washer that secure the adjuster to the mount. (13mm wrench) Let the adjuster hang on the hose. Now remove the mounting bracket (2) (torx30). Remove the cable tie from the wiring harness. |
| 40 | Remove the shock reservoir.
Remove the two rubber bands that secure the reservoir. Pull the shock adjuster back so it is near the reservoir and free of the frame. Loosen the upper shock bolt, but do not remove it yet. |