WHEEL SERVICE

1. To remove the front wheel, loosen the brake cable adjuster all the way and unhook the brake cable at the wheel.

2. Remove the nuts and bolts securing the brake anchor strap to the left fork leg.

3. Remove the axle nut and lock washer.

4. Loosen the pinch bolts which hold the axle (in each fork leg) and pull the axle out.

5. On Pioneer and Plonker models, disconnect the speedometer drive cable and the wheel will be free.

6. When reassembling the front wheel, note that the brake assembly goes on the left (as you are astride the machine) and the speedometer drive assembly is on the right. (1972 Plonker models have the speedometer drive on the left.)

7. Refer to the exploded drawing (Figure 1, page 124) for the correct assembly order of axle spacers and washers.  All models except the 1972 Plonker have a thick washer which fits between the brake assembly and the fork tube and a thin one which fits under the axle nut.

8. If a speedometer is fitted, be sure the driving tabs on the speedometer drive unit fit into, the driving recesses in the hub.

9. The axle is installed from right to left except on 1972 Plonker models.

10. Tighten the axle nut to 60 ft.-lb. on all models except the 1972 Plonker, which requires 50 ft.-lb.

11. Tighten the left axle pinch bolt (right axle pinch bolt on 1972 Plonker) to 15 ft.-lb. Pump the front forks up and down several times to align the fork tubes properly on the axle and tighten the remaining pinch bolt.

12. Reconnect the brake cable and the brake stop arm and reconnect the speedometer cable if fitted.

13. To remove the rear wheel, loosen the rear brake adjustment and disconnect the cable.

14. Disconnect the rear chain at the master link.

15. Loosen and remove the axle bolt and pull the axle out.

16. Pull the wheel to the rear to remove it.

17. When replacing the rear wheel, be sure the brake anchor fits into the anchor plate before the axle is installed.

18. Replace the axle and tighten the axle nut finger tight.

19. Reconnect the chain, making sure the closed end of the master link faces in the direction of chain rotation.

20. Adjust chain free play using the adjusters which bear against the axle so there is about one inch of free play in the chain's longest run when you are sitting in the seat.

21. Sight along the top run of the chain from well behind the machine to be sure the chain is straight.  Tighten or loosen the chain adjusters as necessary and check the chain free play again.

22. Reconnect the rear brake.