Big Bike Parts 62-132 User manual

INSTALLATION INSTRUCTIONS
PART NO. 62-132 ELLIPTICAL DRIVING KIT
YAMAHA ROAD STAR
Copyright
©
2007 by Big Bike Parts, Inc. No
part of this instruction sheet may be
reproduced without the written permission of
Big Bike Parts, Inc.
Revised 10/15/08
TOOLS NEEDED: #2 PHILLIPS SCREWDRIVER 2MM ALLEN WRENCH 8MM WRENCH 14MM SOCKET WRENCH
DRILL THREADLOCKER 10MM WRENCH
13/16” DRILL BIT 6MM ALLEN WRENCH 4MM ALLEN WRENCH
NOTE: THREAD LOCKER SHOULD BE USED ON ALL HARDWARE.
INSTALLATION:
1. DISCONNECT THE NEGATIVE BATTERY CABLE.
2. USING PHILLIPS SCREWDRIVER, REMOVE THE TWO SCREWS ON THE SIDE OF THE HEADLIGHT AND REMOVE THE HEADLIGHT.
3. REMOVE THE COVER OVER OEM TURN SIGNAL LIGHT BAR.
4. USING 8MM WRENCH REMOVE SCREW INSIDE HEADLIGHT HOUSING THAT HOLDS THE OEM LIGHT BAR.
5. ON EACH OEM TURN SIGNAL FOLLOW WIRES INTO THE HEADLIGHT HOUSING AND DISCONNECT THEM. UNPLUG THE BULLET
CONNECTORS.
6. USING 6MM ALLEN WRENCH REMOVE THE TWO BUTTON SOCKET HEAD CAP SCREWS (B) HOLDING THE TURN SIGNAL OEM
LIGHT BAR TO FORKS (KEEP SCREWS).
7. USING 8MM AND 10MM WRENCH REMOVE THE TURN SIGNALS (G) FROM THE OEM LIGHT BAR (KEEP SCREWS AND RUBBER).
8. INSTALL HEADLIGHT MOUNTING PLATE (J) TO HEADLIGHT HOUSING USING M6 - 1.0 X 20MM LONG SOCKET HEAD CAP SCREW
(L) AND SPACER PROVIDED. THE SPACER IS TO GO INTO THE RUBBER BUSHING OF HEADLIGHT HOUSING.
9. INSTALL MOUNTING PLATE (A) TO FORKS USING THE BUTTON SOCKET HEAD CAP SCREWS (B) THAT WERE REMOVED IN STEP
6 AND THE M8 FLAT WASHERS (M) PROVIDED.
10. INSTALL THE SPOT LIGHTS (E) ONTO THE LIGHT BAR (D) USING THE NUTS AND LOCK WASHERS (F) PROVIDED WITH THE SPOT
LIGHTS. POSITION THE LIGHTS. TIGHTEN WITH A 14MM SOCKET.
NOTE: STEPS 11,12,13,15 ARE FOR INSTALLING OEM TURNSIGNAL WITH PURCHASE OF 62-112T ADAPTER.
11. INSTALL EACH OEM TURN SIGNAL (G) ONTO THE NEW TURN SIGNAL ADAPTER (H) ROUTING THE WIRES THROUGH THE HOLE IN
THE ADAPTER. USING THE BOLTS REMOVED IN STEP 7; SECURE THE TURN SIGNAL TO THE ADAPTER.
12. ROUTE THE OEM TURN SIGNAL WIRES AND SPOT LIGHT WIRE INTO THE LIGHT BAR (D). YOU MAY HAVE TO CUT OFF OEM
BULLET CONNECTORS AND ADD NEW ONES AFTER THEY ARE ROUTED.
13. THE TURN SIGNAL ADAPTERS (H) WITH OEM TURN SIGNALS (G) NEED TO BE POSITIONED INTO THE LOWER ENDS OF THE NEW
LIGHT BAR (D) AND SECURED WITH THE SET SCREWS (K). THERE ARE THREE SET SCREWS ON EACH SIDE.
14. USING THE M6 - 1.0 X 16MM LONG BUTTON SOCKET HEAD CAP SCREWS AND LOCK WASHERS (C) INSTALL THE LIGHT BAR (D)
ONTO THE MOUNTING PLATE (A). TIGHTEN SECURELY WITH A 4MM ALLEN WRENCH.
15. RE-ROUTE THE OEM TURN SIGNAL WIRES INTO THE HEADLIGHT HOUSING AND RE-CONNECT AS THEY WERE.
16. LOCATE YOUR BIKE’S BATTERY, FUSE BLOCK AND/OR ACCESSORY TERMINALS AND WIRE ACCORDING TO THE DIAGRAM ON
BACK.
NOTE: IF A 13-207/52-605 SWITCH BLOCK IS PURCHASED, STEPS C & E CAN BE SKIPPED AND PLUG ONE OF THE SWITCHES INTO
THE RELAY.
A) CONNECT THE BULLET CONNECTORS ON BLACK WIRES TO BULLET CONNECTORS ON LIGHT.
B) WIRE SMALL GREEN AND RED HARNESS WITH IN-LINE FUSE DIRECTLY TO BATTERY: RED (+) POSITIVE, GREEN (-) NEGATIVE.
C) FIND A CONVENIENT PLACE TO INSTALL THE SWITCH. DRILL A PILOT HOLE FIRST AND THEN DRILL A 13/16” HOLE. (CAN BE
INSTALLED IN SIDE COVER.)
D) ROUTE WIRE HARNESS AND PLUG THREE SPADE CONNECTORS TO SWITCH PER DIAGRAM: (GREEN=GROUND:
ORANGE=SUPPLY: BLUE=LEAD.)

E) CONNECT THE RING TERMINAL TO THE BATTERY GROUND AND SPLICE THE T-TAP INTO A KEYED POWER SOURCE AND
CONNECT THE MALE SPADE.
F) CONNECT THE REMAINING LEADS (2 BLACK, 1 RED, 1 BLUE, AND 1 GREEN) TO THE RELAY PROVIDED AS PER DIAGRAM.
17. TEST LIGHTS FOR PROPER OPERATION AND ALIGNMENT, REALIGN LIGHTS IF NECESSARY (DO NOT REALIGN BY BENDING
MOUNTING PLATE (A)), BEFORE REINSTALLING ANY REMOVED SIDE COVERS, SEATS, ETC. SECURE RELAY TO KEEP FROM
BOUNCING.