This page contains a Flash digital edition of a book.
>> ASSEMBLING THE BIKE


pulley if you are using the Exile Starter Kit. If you are using one of our pulley covers, remember to install it at the same time as you install the belt and front pulley. Now it is time to fit the oilbag.


Remember to install the electric starter with wires attached before the oilbag is installed. Screw in the outlet fittings using Teflon thread tape or ‘pipe-dope’. Install the oilbag, being sure to include any shims that may have been supplied for spacing between the rubber bushings and the oilbag. Connect up the oil-lines. On the Exile oilbag the right (when sat on the bike) fitting is the vent, the center is the feed to the oilpump and the left is the return from the oil-filter. The instructions with the engine will help you identify where to attach these lines to the engine oil pump. The return line from the oil pump connects to the fitting that feeds into the side of the oil filter. Clean oil then circulates from the center of the filter back to the oilbag. We like to route the oil-lines down behind and under the transmission end cover for a real clean appearance. Where possible, use rubber sheeting around the battery to protect it from vibration damage from contact with the oilbag. On the Exile oilbags we like to route the main positive cable from the starter to the battery (as well as the wire to the starter solenoid) up through the hole in the bottom of the battery box to the battery terminal. BE SURE that there are no sharp edges and that the cable will not be damaged by the movement of the oilbag (it’s rubber mounted). A dangerous short could occur! Install the forward controls and shift linkage (and rear master cylinder and push-rod if separate). Install the exhaust pipes. If you are using the Monster Drag Pipes with a Sprocket Brake Kit, do not install the rear pipe until the final tightening of the axle as you will need to remove the axle to reposition the caliper for brake bleeding. Install the triple trees. Pack the neck


bearings thoroughly and follow the instructions that come with the “Sani- Trees” if you are using our trees. Fork assemblies can now be installed in the trees. It is easier to install a Front Trojan fender before the front wheel is installed. Installation of front wheel and fender should be straight-forward. The front


40


caliper can be fitted and may require some shims (usually included with the caliper) to center it on the rotor. On 15” front wheels it may be a tight squeeze to get the caliper onto the rotor; install the wheel with the rotor only loosely bolted in place and remove the bolts once the axle is tightened. This will allow the caliper to slide onto the rotor before the rotor is permanently installed with loctite.


Handlebar and headlamp installation should require no explanation. The internal throttle is far easier to understand when you have it in front of you and will be supplied with detailed instructions.


directed, as mistakes can be costly. DO NOT ground the battery until you have double-checked everything. A simple multi-meter will enable you to check circuit continuity (i.e. what is connected to what) and will tell you what is live once you hook up the battery. If this sounds way too scary then find some-one else to handle the task, but if you have a reasonable grasp of the properties of electricity and the job each component performs then you may be surprised how easy wiring is. Small in-line circuit breakers are often used as these are easy to hide. Remember, there are no rules to custom bike building. We use a 30 Amp breaker between the battery and the ignition switch, and occasionally a separate 15 Amp breaker between the ignition switch and the light circuit.


Gas-tank mounting should be obvious.


Wiring; this task seems to scare everybody, but on this type of bike it is fairly simple, and can be very satisfying when everything works. Wiring is simply the job of connecting the wires from each electrical component to the other electrical components they are supposed to connect to! Each component comes with instructions telling you where each wire needs to connect. Once the bike is assembled you start with any component and route wires from its terminals to wherever they need to go. Once you have done that for each electrical component, everything will be connected and you will have some spaghetti that constitutes your wiring loom. Run these wires through heat shrink, cut them to the appropriate length, fit terminals as necessary, and pretty soon your bike will be wired. Take your time and be careful to connect as


Make up your brake lines. The Goodridge hoses are of the cut-to-length type and the various fittings are easily attached where necessary. The basic instructions for attaching a fitting to this type of hose are as follows: measure the hose to determine where you want to cut it. Slide the ‘nut’ portion of the fitting on to the hose past the point where you are going to cut. Also, slide on the heatshrink if you are going to cover the stainless hose. A good pair of strong snippers can be used. Alternatively, wrap a piece of masking tape twice around the point where you want to cut. With a fine cut-off wheel (e.g. dremel tool) cut around the hose, just cutting through the braided stainless, not trying to cut all the way through the plastic core. Cut the plastic core cleanly with a sharp blade. Check for any burrs etc. on the cut end of the plastic. Remove the masking tape. The stainless sheathing will spread slightly; gently spread it further with something like a small screwdriver. Put the brass olive onto the end of the plastic and push against a flat solid surface to push it ‘home’. Install the male portion of the fitting onto the end of the hose and slide the nut back down the hose and screw it onto the male part of the fitting. A drop of oil on the threads is a good idea, but do not use thread tape. An in-line hydraulic brake light switch can be used, although it is a little bulky. We like to use the Goodridge banjo bolt that incorporates a brake-light switch – very clean! If you order our ‘Goodridge


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52