INSTALLATION INSTRUCTIONS
PART NO. 63-132
CONTOUR DRIVING LIGHT
63-132L / 63-132BL YAMAHAV-STAR 650 CLASSIC
Revised 3/22/2011
TOOLS NEEDED:
#2 PHILLIPS SCREWDRIVER
4MM ALLEN WRENCH 8MM WRENCH 13/16” DRILL BIT
DRILL
6MM ALLEN WRENCH 10MM WRENCH
THREADLOCKER
14MM SOCKET WRENCH
2MM ALLEN WRENCH
HARDWARE INCLUDED:
(4) M6-1.0 X 16MM LONG BUTTON SOCKET HEAD CAP SCREW
(2) M6 LOCK WASHER
(1) M6-1.0 X 20MM LONG SOCKET HEAD CAP SCREW
(1) SPACER
(4) M4-0.7 X 6MM SOCKET HEAD SET SCREW
(2) M8-1.25 HEX NUT
(2) M4-0.7 X 3MM SOCKET HEAD SET SCREW
(2) M8 LOCK WASHER
NOTE: THREADLOCKER 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.
ON EACH OEM TURN SIGNAL FOLLOW WIRES INTO THE HEADLIGHT HOUSING AND DISCONNECT THEM. UNPLUG THE BULLET
CONNECTORS.
5.
USING 6MM ALLEN WRENCH REMOVE THE TWO SOCKET HEAD CAP SCREWS (B) HOLDING THE TURN SIGNAL OEM LIGHT BAR TO
FORKS (KEEP SCREWS).
6.
USING 8MM AND 10MM WRENCH REMOVE THE TURN SIGNALS (G) FROM THE OEM LIGHT BAR (KEEP SCREWS AND RUBBER).
7.
INSTALL MOUNTING PLATE (A) TO FORKS USING SCREWS THAT WERE REMOVED IN STEP 5.
8.
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 9,10,11 AND 12 ARE FOR INSTALLING OEM TURN SIGNALS WITH 62-112T ADAPTERS.
9.
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 6 SECURE THE TURN SIGNAL TO THE ADAPTER.
10. ROUTE THE OEM TURN SIGNAL WIRES AND SPOT LIGHT WIRE UNDER THE LIGHT BAR (D). YOU MAY HAVE TO CUT OFF OEM BULLET
CONNECTORS AND ADD NEW ONES AFTER THEY ARE ROUTED.
11. 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), THE SHORT SET SCREWS GO IN THE BACK HOLES. THERE ARE THREE SET
SCREWS ON EACH SIDE.
NOTE: THERE ARE THREE DIFFERENT SETS OF MOUNTING HOLES ON THE LIGHT BAR THIS IS FOR ADJUSTABILITY BETWEEN
BIKES. CHOOSE THE ONES THAT WILL GET THE LIGHT BAR CLOSEST TO THE FORKS WITHOUT HITTING ANYTHING.
12. 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.
13. RE-ROUTE THE OEM TURN SIGNAL WIRES INTO THE HEADLIGHT HOUSING AND RE-CONNECT AS THEY WERE.
14. LOCATE YOUR BIKE’S BATTERY, FUSE BLOCK AND /OR ACCESSORY TERMINALS AND WIRE ACCORDING TO THE DIAGRAM ON
BACK.
NOTE: IF A 13-207 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.)
Copyright
©
2005 by Big Bike Parts, Inc. No
part of this instruction sheet may be
reproduced without the written permission of
Big Bike Parts, Inc.
