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449 viewsThe pin is missing. Looks melted...??? Without this pin set in the case halves the planetary ring rotates and doesn't allow the forward gear to rotate properly.
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448 viewsConnect the wires to the power plug. Now all the ignitor and ballast wires are attached so you can push them further into and down inside the headlight bucket. Now you can loop in the other zip-tie to secure the ballast, cutting notches in the hourglass brace like I did if you want. If you removed the high-beam bulb you can now put it back in, along with its wires.
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448 viewsRepaired pin cut, ground further, and beveled. Fits in the hole nicely! Remember, the planetary ring will move side-to-side so make sure the pin isn't butted against the end of the hole. Allow for the movement.
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447 views...and now it's in the 'locked' position. I noticed many of the electrical connectors had some sort of lock on them. If you see a red tab/button then that's a connector lock.
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447 viewsNext, I used a 15/64" (almost 6mm which would work fine) and hand drilled the hole for the grommet (yes, I twisted it with my bare fingers). I wanted to make sure I drilled straight and using a hand-held drill would've caused the hole to be at a slight angle due to the head light housing interfering with the drill chuck.
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447 viewsRemoving the one-way retaining washer is a pain in the butt. Chances are very good that you could end up breaking the pin...not that it's a big deal if that happens, honestly. I did this on the left side to remove the turn signal electrical connector away from the rest of the harness, then pushed the retainer back on.
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446 views
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446 viewsHere's the VR. The center pin is a ground and the easiest way to ground it is to CAREFULLY bend it back onto the backside of the VR body. It will then be pressed against the gauge cluster body that is grounded. The pins are delicate and if you bend them too much they will break!
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446 viewsNow the bar-end mount is up two inches at 34" high.
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446 viewsThe ground lug I used on the left side. Use a ring connector for the grounds. This insures the nut will still make a connection even if the nut gets loosened.
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446 viewsI used a 5/8" socket to support the bearing so I could drive out the push rod.
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446 viewsThe red circled part shows why the lens needs to be angled out when removing it. That hook helps hold the lens in to the housing. The end opposite the hook is where the screw goes.
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445 views
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445 viewsHere's what they look like. A simple and effective design. Here's where you can get 'em:
http://www.bhpbikeparts.co.uk/content/products/
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445 viewsRight side ground...had to use a 10mm box wrench (spanner).
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Day example.445 viewsDay time demo. Also on YouTube.com at http://www.youtube.com/watch?v=Sr75SJdNsJQ&feature=relmfu
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445 viewsSize comparison of the incandescent (left) bulb vs. the LED unit (right). Though the LED unit is taller it will still fit inside the signal housing with room to spare.
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445 viewsCloser-up. Exploded view. Notice pin is short...it came to us broken.
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444 viewsHarbor Freight trim tool (nylon kit, non-scratching, less than $6) used to pry the light switch out. Very easy.
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444 viewsFog harness using a hook on the right side radiator fan surround.
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