| 1. | Remove seat. | |
| 2. | See Figure 1. Properly orient control module (1). | |
| 3. | Loosely install screws (3) in the rearward holes, then mark the locations of the forward mounting holes. | |
| 4. | Remove screws and control module. | |
| 5. | Drill two 6.4 mm (0.25 in) holes at the marked locations. | |
| 6. | Connect the auxiliary harness to the control module. | |
| 7. | Install P-clip (8) over power supply lead of the auxiliary harness. | |
| 8. | Install the control module as follows: a. Secure the left side rear corner of the control module with a screw (3) and washer (2). Secure the right side rear corner, P-clip and power supply lead of the auxiliary harness with the screw (3). b. Secure the front of the control module with two 1/4-20 x 1/2 inch screws (4), 1/4 x 1 inch washers (5), 1/4 x 1/16 inch washers (6) and locknuts (7). c. Tighten the screws to 8.1–9.5 N·m (72–84 in-lbs). |
| 1 | Emergency light and siren control module |
| 2 | Washer 1/4 x 9/16 |
| 3 | Screw 1/4-20 x 1/2 TORX (2) |
| 4 | Screw 1/4-20 x 1/2 TORX (2) |
| 5 | Washer 1/4 x 1 (2) |
| 6 | Washer 1/4 x 9/16 (2) |
| 7 | Locknut 1/4-28 x 20 (2) |
| 8 | P-clip |
| 1. | See Figure 2. Remove two stock screws and brake reservoir clamp (1). | |
| 2. | Install brake reservoir clamp, two spacers (2), emergency light control switch (3) and two screws (4). Tighten screws to 9–10.2 N·m (80–90 in-lbs). NOTE The switch harness will be secured at the same time as the wind deflector light harness. | |
| 3. | Removing the two mounting pins and two well nuts from the windshield and pull the windshield up sharply to remove it from the windscreen. Remove the windscreen by removing the six screws. | |
| 4. | Route the harness along the handlebar following the existing wiring under the instrument cluster and forward to the auxiliary harness. | |
| 5. | Connect the 4-place emergency light control switch connector to the 4-place auxiliary harness connector with the blue, gray, brown and red/white wires. |
| 1 | Brake reservoir clamp |
| 2 | Spacer (2) |
| 3 | Screw (2) |
| 4 | Emergency light switch |
| 1. | Spread the inboard ears of the wind deflector and place them over the ends of the pivot shaft and riser. Snap the slot at the outboard end into the groove in the end cap. | |
| 2. | Fasten the wind deflector to the pivot shaft and riser with two M5 x 16 truss head screws. Tighten the screws to 2.7–4.1 N·m (24–36 in-lbs). NOTE When securing the right side wind deflector harness, also secure the emergency light switch harness. | |
| 3. | Route the emergency light harness (7) along the handlebar, following the handlebar control harness under the instrument cluster and forward to the auxiliary harness. Remove the two existing cable straps and secure the emergency light and handle bar control harnesses to the handlebar with two new cable straps. | |
| 4. | Repeat procedure for the opposite side. |
| 1. | Behind windscreen, disconnect yellow lead from the air horn and connect it to the spade connector of the auxiliary harness. | |
| 2. | See Figure 8. Install siren speaker bracket to V-bracket with four 1/4-20 x 3/4 inch screws (1) and 1/4-9/16 inch washers (2). Tighten the screws to 25–27 N·m (18–20 ft-lbs). NOTE Terminal numbers are indicated on the siren speaker driver. | |
| 3. | Connect the brown wire of the auxiliary harness to terminal 1 of the siren speaker driver (6). Connect the orange wire of the auxiliary harness to terminal 2 of the siren speaker. Secure the wires using the clip in the upper inboard hole of the siren bracket plate. | |
| 4. | Install siren speaker driver to siren speaker bracket with four screws (9) and washers (2). Tighten the screws to 14–16 N·m (10–12 ft-lbs). | |
| 5. | Install siren cover (5) and three 1/4-20 x 3/4 inch screws (3), 1/4 inch lockwashers (4) and 1/4 inch washers (2) to the siren speaker driver. Tighten the screws until the lockwashers are compressed but not bottomed out. Do not over tighten. | |
| 6. | Install two steel gaskets (13) then one fiber gasket (14) over the speaker driver. | |
| 7. | Install outer flare (10) onto the siren speaker driver. | |
| 8. | Install two rubber gaskets (16) and then two fiber gaskets (15) into the inner flare (11). | |
| 9. | Install inner flare to the siren speaker. |
| 1. | Remove the upper front fender by removing the two screws and washers. | |
| 2. | See Figure 7. Apply a small amount of Loctite 243 (blue) to the fender mounting screws. Install front fender (18) and assembled front light module to the lower fork clamp with two 1/4-20 x 11/16 inch screws (14) and 5/16 x 9/16 inch washers (15). Tighten screw to 5.5–6.7 N·m (48–60 in-lbs). | |
| 3. | Insert spacer (17) between light module and headlight, then secure fender and front light module to the headlamp with 1/4-20 x 1 inch screw (16). Tighten screw to 4–5.5 N·m (36–48 in-lbs). | |
| 4. | Route the left side and right side front light module harnesses up the forks and behind the windscreen. Connect to the auxiliary harness. |
| 1 | Cable strap (4) |
| 2 | Grommet |
| 3 | Rear harness (2) |
| 1 | Vertical emergency light |
| 2 | Horizontal emergency light |
| 1. | Disconnect emergency light connector from auxiliary harness, then use terminal tool (B-49454) to remove the round emergency light terminals from the emergency light connector housing. | |
| 2. | See Figure 4. Remove screw (3), nut (2), washer (7) and P-clip (6) retaining the round emergency light harness. | |
| 3. | Remove nut (9), washers (10), spacer (11), screw (12) and round emergency light (8). | |
| 4. | Apply a small amount of Loctite 243 (blue) to the screw, then install nut, washers, spacer, screw and new round emergency light. Tighten the screw to 9.5–12.2 N·m (84–108 in-lbs). | |
| 5. | Route round emergency light harness through P-clip. | |
| 6. | Apply a small amount of Loctite 243 (blue) to the screw, then install the P-clip, screw, nut and washer. | |
| 7. | Install terminals to the new emergency light leads, then install the terminals into the connector housing. | |
| 8. | Connect emergency light(s) to the auxiliary harness. |
| 1. | Remove seat. | |
| 2. | Remove air cleaner assembly. | |
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) | ||
| 3. | Disconnect battery negative cable (black) from battery negative (-) terminal. | |
| 4. | Pull back terminal cover boot on battery positive cable (red). | |
| 5. | Disconnect battery positive cable from battery positive (+) terminal. | |
| 6. | Remove battery. | |
| 7. | Remove electronic control module. | |
| 8. | Remove windscreen and windshield. | |
| 9. | Remove left side air scoop. |
| 1. | Install auxiliary harness starting at the seat area and guiding and pulling it toward the front of vehicle. NOTE When routing the harness through the shock tower, the siren lead break out on the auxiliary harness will line up with the sensor leads on the main harness. If the auxiliary harness is laid out in this manner it will make sure that the harness is installed in the correct location. | |
| 2. | Connect rear auxiliary harness at triple tail and lighting/siren control module. | |
| 3. | Route harness through shock tower toward the front of vehicle. | |
| 4. | Connect auxiliary harness behind windscreen. | |
| 5. | Tighten wire harness guide at steering head. | |
| 6. | Install one cable strap securing siren harness lead to harness routing tray across frame behind the intake assembly. | |
| 7. | Install four cable straps securing auxiliary harness to the main harness. | |
| 8. | Install ignition coil: a. Connect spark plug cables to ignition coil. b. Install ignition coil and fasteners. Tighten fasteners to 13.6–16.3 N·m (120–144 in-lbs). c. Connect ignition coil to main harness connector [83]. NOTE
| |
| 9. | Install fan: a. Install cooling fan and rotate counterclockwise into position. b. Install cooling fan fasteners. Tighten fasteners to 1.4–4 N·m (12–36 in-lbs). | |
| 10. | Install rear shock absorber assembly and reservoir. | |
| 11. | Lower rear wheel to ground and remove lift or jack from under muffler. | |
| 12. | Install right side engine shroud air scoop. Tighten fasteners to 1.4–4 N·m (12–36 in-lbs). | |
| 13. | Install siren to V-bracket. NOTE When installing the left side air scoop, it is necessary to make sure that the voltage regulator and alternator wiring harnesses are not trapped between the air scoop and cylinder head. | |
| 14. | Install left side air scoop. Tighten fasteners to 1.4–4 N·m (12–36 in-lbs). | |
| 15. | Install windscreen and six fasteners and washers. Tighten fasteners to 1.1–1.4 N·m (10–12 in-lbs). | |
| 16. | Install windshield onto windscreen: a. Align the mounting pins of the windshield with the mounting grommets on the windscreen and push in place to install. Pull on windshield to verify attachment. b. Insert well nuts into the windshield and windscreen holes. c. Install mounting screws and tighten 8-10 revolutions into the well nuts. | |
| 17. | Install electronic control module: a. Install ECM to electrical bracket. Tighten fasteners to 8–11 N·m (36–60 in-lbs). b. Connect main harness connectors [10] and [11] to the ECM. | |
Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) | ||
| 18. | Install battery. a. Connect battery positive cable from battery positive (+) terminal. b. Install terminal cover boot on battery positive cable (red). c. Connect battery negative cable (black) to battery negative (-) terminal. NOTE In order to perform the next step in this procedure, make sure the battery is fully charged to energize the emergency light and siren control module. | |
| 19. | Verify operation of all emergency components. | |
| 20. | Install air cleaner assembly. | |
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) | ||
| 21. | Install seat. |
| 1 | Reflector |
| 2 | Side case |
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Deflector, left, with LED light mount | M1188.1AU |
2 | Deflector, right, with LED light mount | M1187.1AU |
3 | Emergency light, rectangular, blue | Y0651.1AU |
Emergency light, rectangular, red | Y0651A.1AU | |
4 | Bezel, rectangular (2) | Y1027.1AU |
5 | Screw, No. 4 x 5/8 inch, (4) | CA0110.1AU |
6 | Locknut, No. 8, (4) | 7864 |
7 | Sub-harness, lighting front (2) | Y0469.1AU |
8 | Washer, No. 8 x 7/16 x 3/64 inch, (4) | 6192 |
9 | Screw, 8-32 x 7/8 inch, (4) | AN0807.14CDZB |
10 | Spacer, light switch mounting (2) | CH0022.1AU |
11 | Light switch assembly | Y0443.1AU |
12 | Screw, M6-1.0 x 50 mm, (2) | A06050.3CVB |
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Mount, main front light | Y1012.1AU |
2 | Locknut, No. 6, nylon insert, (4) | 60031-61 |
3 | Screw, No. 6 x 5/8 inch, (4) | 3225 |
4 | Bezel (2) | Y1027.1AU |
5 | Emergency light, rectangular, blue, vertical | Y0652.1AU |
Emergency light, rectangular, red, vertical | Y0652A.1AU | |
6 | P-clip (4) | CM0006.1AU |
7 | Washer, 5/32 x 3/8 x 1/32 inch, (4) | 6029 |
8 | Emergency light, round, blue | Y0650.1AU |
Emergency light, round, red | Y0650A.1AU | |
9 |
| Not Sold Separately |
10 |
| Not Sold Separately |
11 |
| Not Sold Separately |
12 |
| Not Sold Separately |
13 |
| Not Sold Separately |
14 | Screw, 1/4-20 x 11/16 inch shoulder TORX®, (2) | CA0018.02A8 |
15 | Washer, 5/16 x 9/16 inch, (2) | BA0509.6 |
16 | Screw, 1/4-20 x 1 inch | AA0408.11CZB |
17 | Spacer | Y1014.1AU |
18 | Front fender, upper | M1662.1AUAMBE |
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Screw, 5/16-18 x 1.0 inch, (4) | AA0508.2CXZB |
2 | Washer, 1/4 x 9/16 inch, (7) | BA0409.1Z |
3 | Screw, 1/4-20 x 3/4 inch, (3) | AA0406.11CJXZB |
4 | Lockwasher, 1/4 x 31/64 x 1/16 inch, (3) | 7036 |
5 | Siren cover | M0115.1AU |
6 | Siren speaker driver | Y0684.1AU |
7 | Washer, 5/16 x 1/2 inch, (4) | CB0002.9A7 |
8 | Siren mount | L2246.1AU |
9 | Screw, 1/4-20 x 3/4 inch TORX, (4) | AA0406.11CXZB |
10 | Outer flare | Y0682.1AU |
11 | Inner flare | Y0683.1AU |
12 | Gasket kit, speaker | Y0687.1AU |
13 |
| Not Sold Separately |
14 |
| Not Sold Separately |
15 |
| Not Sold Separately |
16 |
| Not Sold Separately |
17 | Screw | Not Sold Separately |
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Top case, with brackets and reflectors | M0926D.1AU |
| M0401.1AU | |
| M0402.1AU | |
| M0403.1AU | |
| M0404.1AU | |
| M0405.1AU | |
| M0406.1AU | |
| M0407.1AU | |
| M0408.1AU | |
| M0409.1AU | |
| M0411.1AU | |
2 |
| M0410.1AU |
3 | Side case, right | M0917.1AU |
Side case, left | M0918.1AU | |
| M0404.1AU | |
| M0411.1AU | |
| M0412.1AU | |
| M0413.1AU | |
| M0414.1AU | |
| M0415.1AU | |
| M0416.1AU | |
4 |
| M0410.1AU |
5 | Bracket, left saddlebag | M0254.1AU |
6 | Bracket, right saddlebag | M0255.1AU |
7 | Protective tape (9) | 90118-05Y |
8 | Bracket, X-brace | M0253.1AU |
9 | Reflector, red (2) | 59259-90 |
10 | Bracket, mounting, top case, upper | M0261.1AU |
11 | Bracket, mounting, top case, lower | 92308-05Y |
12 | Emergency light, horizontal, blue | Y0651.1AU |
Emergency light, horizontal, red | Y0651A.1AU | |
13 | Washer, 21/64 x 11/16 inch, (10) | 7082Y |
14 | Washer, 17/64 x 9/16 inch, (2) | 7083Y |
15 | Locknut, 1/4-20 x 7/16 inch, (4) | 7716 |
16 | Screw, lock patch, 1/4-20 x 5/8 inch, (4) | AA0405.21CJLZB |
17 | Screw, TORX®, 1/4-20 x 3/4 inch, (2) | AA0406.11CZB |
18 | Screw, hex, flange, lock patch 1/4-20 x 1 inch, (4) | AA0408.21CXZB |
19 | Screw, hex, flange, lock patch 1/4-20 x 2 inch, (4) | AA0416.21CXZB |
20 | Screw, hex, flange, lock patch 5/16-18 x 1 inch, (4) | AA0508.21CXZB |
21 | Washer 1/4 x 3/4 inch, (2) | BA0412.2Z |
22 | Screw, 6/32 x 1/2 inch, (6) | 2539 |
23 | Screw, No. 6 x 5/8 inch, (2) | 3225 |
24 | Bezel, single (4) | Y1027.1AU |
25 | Bezel, double (2) | Y1027A.1AU |
26 | Reflector, red (2) | M0400.1AU |
27 | Screw, No. 8-32 x 1/2 inch Pozidrive panhead, (4) | 2612 |
28 | Emergency lighting bracket, right | Not Sold Separately |
Emergency lighting bracket, left (not shown) | Not Sold Separately | |
29 | Washer, No. 8 x 7/16 x 3/64 inch, (8) | 6192 |
30 | Locknut, No. 8, (4) | 7864 |
31 | Screw, No. 8 x 3/8 inch, (4) | 2808 |
32 | Locknut, No. 6, (2) | 60031-61 |
33 | Washer, 5/32 x 3/8 x 1/32 inch, (2) | 6029 |
34 | P-clip (2) | CM0006.1AU |
35 | Washer, 1/4 x 9/16 inch, (2) | BA0409.1Z |
36 | Rear emergency light harness (2) | Y0470.1AU |
37 | Grommet | M0231.1AKG |
38 | Cable strap (14) | Y0303.2B |