National Cycle N925 User manual

PARTS LIST
INSTALLATION AND OWNER’S MANUAL
Light Bar N925 for Installation to:
Kawasaki® VN1500D&E and VN800B Pages 1,2,3 and 5
Kawasaki®VN1600 Pages 1, 4 and 5
QTY. PART NO. DESCRIPTION
1 N925 Light Bar Assembly
Bag 154
6 80-850000-000 Scotchlok Connectors
2 49-490521-000 Washer Flat (for VN1600 only)
2 50-571100-000 Screw, M6 x 16 (for VN1600 only)
Tools needed to remove fuel tank.
Screw Driver, #2 Phillips
Socket 10mm and Ratchet Wrench
Socket 27mm, 3” Extension and Wrench
Hex Key Wrench, 5mm
Slip Joint Pliers
Floor Jack capable of lifting front of motorcycle.
Motorcycle Owner’s Manual
Screw Driver, #2 Phillips
Screw Driver, Flat Blade
8mm Wrench
Slip Joint Pliers
Motorcycle Owner’s Manual
Page 1 of 5 10-110725-000 06/03
PREPARATION VN1500D and VN800B PREPARATION VN1600
Make certain the motorcycle is positioned securely on
its sidestand or a work stand.Cover the front fender
to avoid scratches due to a dropped part or tool.
Make certain the motorcycle is positioned securely
on its sidestand or a work stand.Cover the front
fender to avoid scratches due to a dropped part or
tool.
2. Remove the head lamp from the Headlight Shell
(Screwdriver), set aside.
3. Disconnect Turnsignal Wires Inside headlight Shell.
4. Remove Turnsignals: (Refer to the motorcycle owner’s
manual)
REPLACEMENT PARTS and ACCESSORIES
Order parts through your local dealer or contact National Cycle.
N925
Description Part No.
Light Head Assembly 90-910501-000
Lamp Assembly E13/DOT
Reflector, Lens and Bulb 90-901011-000
Halogen H3 Bulb 90-901015-000
Turn Signal
Assembly 90-930921-000
Turn Signal Lens 90-930213-000
Turn Signal Bulb Only: Bulb 1157 Available at Most Auto Parts Stores.
Light Bar Accessories
Chrome Visor N9005
Alternate Thumb Switch N9001
TOOL LIST VN1600 Installation
TOOL LIST VN1500D&E and VN800B Installation
Tips for facilitation of operation, control
and adjustment, as well as maintenance
work.
Special notes and cautionary measures
which can prevent damage to the motor-
cycle.
Left and Right side of motorcycle is determined
while sitting on the bike.

1. Loosen the pinch bolts on the upper Triple Clamp (5mm Hex
Key).
2. Remove the bolt at the center of the upper Triple Clamp (27mm
Socket).
3. Lift the front of the motorcycle so there is no weight on the front
wheel (Floor Jack).
4. Carefully lift the upper Triple Clamp off the fork.
5. Remove the fork covers (Screwdriver).
6. Remove the Turn signals (8mm Wrench & 10mm Socket).
7. Replace the fork covers, fully tightening the holding screws.
8. Reinstall the upper Triple Clamp, tightening the fasteners to
manufacturer's specified torque.
9. Lower the Floor Jack, you are done with it now.
10. Verify tightness of the center bolt and pinch bolts on upper
Triple Clamp.
Mount the Light Bar Assembly
1. Remove the Headlight Shell mounting screws under the
Headlight Shell (8mm Wrench & 10mm Socket).
2. Place the Light Bar Assembly so the center mount bracket is
between the lower Triple Clamp and the mounting bracket for the
Headlight Shell.
NOTE: Watch for the bushings for the Headlight Shell mounting
screws, they will fall out!
3. Replace the Headlight Shell mounting screws and nuts, do not
tighten at this time.
4. Make sure the wires coming out of the Light Bar assembly cen-
ter slot will not be pinched, position the Light Bar to be centered on
the Lower Triple Clamp, then tighten the Headlight Shell mounting
screws to manufacturer's specified torque.
INSTALLATION VN1500D&E and VN800B
INSTRUCTION FOR VN1500D&E AND VN800B
Page 2 of 5 10-110725-000 06/03

Wire the Light Bar Assembly
1. Route the Light Bar Assembly wires over the Triple Clamp
and into the Headlight Shell.
2. Attach the wires according to the Right and Left Side
Instructions Below. (Scotchlok connectors & Slip Joint Pliers)
Watch the instruction for the differences in wire color
between the VN1500 and VN800.
Right Side of Light Bar
1. Red wire from the Light Bar connects to the Gray wire in
turn signal harness
2. Black wire from the Light Bar connects to Red wire with
blue tracer (VN1500) or solid blue (VN800) in turn signal har-
ness.
3. Blue wire from the Light Bar connects to:
Red wire with yellow tracer on headlight connector
(lo-beam operation.)
Red wire with black tracer on headlight connector
(Hi-beam operation.)
Left Side of Light Bar
1. Red wire from the Light Bar connects to Green wire in turn
signal harness
2. Black wire from the Light Bar connects to Red wire with
blue tracer (VN1500) or solid blue (VN800) in turn signal har-
ness.
3. Blue wire from the Light Bar connects to:
Red wire with yellow tracer on headlight connector
(lo-beam operation)
Red wire with black tracer on headlight connector
(Hi-beam operation)
Through Wire
Wire from light
bar, insert to stop
INSTRUCTION FOR VN1500D&E AND VN800B
Page 3 of 5 10-110725-000 06/03
WIRE THE LIGHT BAR VN1500D&E and VN800B

1. Remove the screws from the sides of the headlight shell
(Phillips screwdriver). Gently pry the headlight ring from
the shell- there is a notch for this on the left side of the shell
(flat screwdriver). Disconnect the plug on the back of the
headlight and set the headlight assembly and screws aside
for re-use.
2. Unplug the turn signal leads. They are the long, thin wire
terminals.
3. Feed the turn signal leads (the ones with the male pin
terminals) out of the back of the headlight shell.
4. Remove the turn signal bar from the lower triple clamp
(8mm wrench). Be careful while pulling the wires out of
the fork cover.
INSTALLATION - LIGHT BAR for VN1600
1. Using the M6 x 16 Screws provided and the flat washers
removed in Setup Step 4 from the Turn Signal Bar, attach
the Light Bar to the lower fork crown. Tighten the screws
securely Figure 1.
2. Route the wires from the light bar in the same location as
the turn signal bar.
Wire the Light Bar Assembly for VN1600
1. Route the Light Bar Assembly wires into the Headlight
Shell.
2. Attach the wires according to the Right and Left Side
Instructions Below. (Scotchlok connectors & Slip Joint
Pliers)
Left Side of Light Bar for VN1600
1. Red wire from the Light Bar connects to Green wire in
turn signal harness
2. Black wire from the Light Bar connects to Red wire with
blue tracer in turn signal harness.
3. Blue wire from the Light Bar connects to:
Red wire with yellow tracer on headlight
connector (lo-beam operation)
Red wire with black tracer on headlight connector
(Hi-beam operation)
Right Side of Light Bar for VN1600
1. Red wire from the Light Bar connects to the Gray wire in turn
signal harness
2. Black wire from the Light Bar connects to Red wire with blue
tracer in turn signal harness.
3. Blue wire from the Light Bar connects to:
Red wire with yellow tracer on headlight connector
(lo-beam operation.)
Red wire with black tracer on headlight connector
(Hi-beam operation.)
Through Wire
Wire from light
bar, insert to stop
INSTRUCTION FOR VN1600
Page 4 of 5 10-110725-000 06/03
INSTALLATION - SETUP VN1600
Flat Washer
Route
wires to
this notch
Figure 1.
M6 x 16 Screw

HORIZONTAL AIM
A. To adjust the Spotlights or Turnsignals right or left gently
rotate the lamp into the correct position. In the event that the
lamps become loose, refer to the procedure for vertical
adjustment.
2. VERTICAL AIM
(In addition to the tools needed for
installation)
Hex Key, 5/32" or 4mm
Deep Socket and Socket ; 9/16" or 14mm
Aslotted 9/16” Socket (SNAP ON part #FRX 181, is one
source) will allow adjustment without having to
pull wires
A. Disconnect wire connections inside the Headlight Shell.
B. Pull the wires out of the Light Bar tube.
C. Turn the Turnsignal to provide access to the mounting screws.
D. Unscrew the Turnsignal mounting screws and remove the
Turnsignal (Hex Key).
E. Push the Spotlight wire up into the Spotlight Shell.
F. Loosen the nut on the Spotlight stud (Deep Socket).
G. Now, adjust the Spotlight. Reconnect the spotlight wire and illumi-
nate to verify its projection.
H. Push wire into the Spotlight Shell.
I. Firmly retighten the nut on the Spotlight stud.
J. Pull the wire out of the Spotlight Shell.
K. Reassemble in reverse order of disassembly.
L. Adjust the Spotlights and Turnsignals horizontally by rotating into
position.
M. Verify operation of the lights.
National Cycle, Inc. PO Box 158 Maywood, IL 60153-0158 USA
708-343-0400 Fax:[phone] www.nationalcycle.com e-mail: [email protected]
Page 5 of 5 10-110725-000 06/03
MAINTENANCE AND CARE
ADJUSTMENT PROCEDURE
The high quality chrome finish of your National Cycle light bar can bemaintained with any quality chrome cleaner and /or
polish.
Replacement Parts: Refer to page 1.