Materials and Tools:
- New front end kit (usually includes Triple Tree, Forks, Fenders, etc.)
- Handlebars
- Grips
- Brake and Clutch Levers
- Throttle Cable
- Brake Line
- Spacers (if needed)
- Various nuts, bolts, and fasteners
- Basic tools (wrenches, screwdrivers, hex keys, mallet, etc.)
Steps:
1. Disassembly:
- Start by removing the handlebars, grips, and any other components attached to the existing front end.
- Disconnect the brake line and throttle cable.
- Loosen and remove the axle nuts on both sides of the front wheels.
- Remove the front wheel.
2. Triple Tree Removal:
- Locate and remove the bolts or nuts holding the Triple Tree in place.
- Carefully remove the Triple Tree assembly, paying attention to any spacers or bearings that may need to be transferred to the new setup.
3. Forks and Front End Installation:
- Install the new forks into the Triple Tree assembly, making sure to use any necessary spacers or bearings.
- Secure the forks in place using the provided bolts or nuts.
4. Front Wheel and Axle:
- Install the front wheel onto the forks, ensuring proper alignment.
- Secure the wheel using the axle nuts on both sides.
- Tighten the axle nuts securely.
5. Fenders and Nose:
- Mount the new front fenders and any additional nose pieces according to the kit instructions.
- Use the provided hardware to secure the fenders and nose to the forks and Triple Tree.
6. Handlebar Installation:
- Attach the new handlebars to the Triple Tree using the appropriate bolts and nuts.
- Tighten the bolts securely to ensure a strong connection.
7. Controls and Cables:
- Connect the brake line and throttle cable to the respective levers and mechanisms.
- Install new grips on the handlebars.
8. Final Checks:
- Ensure all bolts, nuts, and fasteners are securely tightened.
- Check the brake lever and throttle functionality.
- Test the suspension by applying pressure to the forks and ensuring they move smoothly.
- Verify that the front wheel spins freely and is properly aligned.
Remember, safety is paramount when performing any modifications to your vehicle. If you're unsure about any steps or procedures, it's always best to consult a professional mechanic or refer to the specific instructions provided with the new front end kit.
