Evo Sportster 200 Kit Installation Instructions

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REAR FORK
REMOVAL/DISASSEMBLY

NOTE
Mark all hardware as it is removed so that it may be returned to it's orginal location.

  1. See Figure2-92 right.  Remove rear wheel 
  2. Remove rear brake caliper assembly. See Rear Brake Caliper.
  3. Remove rear shock absorber nuts & washers from rear fork.
  4. Remove rear belt guard and debris deflector. Remove belt.
  5. Remove socket screw (#11)
  6. Remove pivot (#1). Support rear fork and pull fork assembly from frame.

CAUTION

Carefully mark all bearing components as they are removed so that they may be returned to their original locations.  Do Not intermix bearing components.

NOTE

REMOVE BEARING RACES (8) AND PIVOT BUSHING (4) ONLY IF REPLACEMENT IS REQUIRED. THE COMPLETE BEARING ASSEMBLY MUST BE REPLACED AS A UNIT WHEN REPLACEMENT IS NECESSARY. DO NOT INTERMIX BEARING COMPONENTS.

       7.  Carefully press bearing outer races (8) from from fork. Remove lock ring (9).
      8.  Remove pivot spacer (5). Press pivot busing (4) from fork assembly.

CLEANING AND INSPECTION

  1. Clean all components in solvent and blow dry. Carefully inspect all bearing components for wear and/or corrosion.  Replace complete bearing assembly if any component is damaged.

  2. Check that rear fork is not bent or twisted. Replace if damaged.

 


Figure 2-92

  ASSEMBLY
  1. See Figure 2-92 If necessary install new lock ring (9) and press new outer races (8) into position.

NOTE- Roller bearing assemblies are shipped assembled as a unit. Do not intermix components.  Mark all components so they may be correctly installed.

   2.  Coat bearing components with bearing grease and assemble.

CAUTION

Bearing space (10) must be installed between inner races (7) or bearing failure can result.

   3. Press dust shields (6) ovr bearing inner races (7) with the lipped side in.
   4.  If pivot bushing (4) must be replaced, press it into rear fork (2)
   5.  Insert pivot spacer (5) into pivot gushing (4) with chamfered end facing outward thoward socket head screw.

WARNING

Pivot spacer (5) must be installed with chamfered end outward toward socket head screw (11) or  insufficient clamp load between rear fork pivot and frame may adversely affect handling which could result in death or serious injury.

   INSTALLATION
  1. See Figure 9-92 above. Slide rear fork assembly into position.
  2. Holding fork assembly in position, install povot bolt (1). Apply two or thre drops of Coctite 242 Blue on threads of screw (11). Thread screw into internal treds of pivot bolt (1) and thighten to 50 ft-lbs.(68Nm) torque.
  3. Install belt guard and debris deflector.
  4. Install shock absorbers onto rear fork.
  5. Install rear brake caliper assembly.
  6. Install rear Wheel.
Transmission Pulley Cover
GENERAL

The rear compartment of the left and right crankcase halves for the transmission case.  An access cover (door) allows removal of transmission components without removing the engine or disassembling (splitting) the crankcase.

REMOVAL


  1. Remove exhaust system.
  2. See Figure 6-20 below. Remove footrest, brake pedal, sprocket cover (5) and rear brake master cylinder from right side of motorcycle.

  1.    Place a drain pan under the engine. Remove drain plug, and drain lubricant from primary drive/transmission.
  2. See Figure 6-21 right. Place transmission in first gear. Remove two socket head screws (5) and lockplate (4).

NOTE: Transmission sprocket nut has left-hand threads. Turn nut clockwise to loosen and remove from main drive gear shaft.

  1. Remove transmission sprocket nut (3) from main drive gear shaft (1).

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