TOOLS NEEDED:
PHILLIPS SCREWDRIVER 12MM SOCKET WRENCH
10MM WRENCH 14MM SOCKET WRENCH
8MM WRENCH
6MM ALLEN WRENCH
2MM ALLEN WRENCH THREADLOCKER
DRILL
13/16” DRILL BIT
4MM ALLEN WRENCH
HARDWARE INCLUDED:
(3) M6-1.0 X 16MM LONG BUTTON SOCKET HEAD CAP SCREW
(3) M6 LOCK WASHER
(4) M4-0.7 X 6MM LONG CUP POINT SOCKET HEAD SET SCREW
(2) M4-0.7 X 3MM LONG CUP POINT SOCKET HEAD SET SCREW
(2) M6-1.0 X 10MM LONG BUTTON SOCKET HEAD CAP SCREW
(2) M8-1.25 NYLOCK HEX NUT
(2) M8 LOCK WASHER
NOTE: THREAD LOCKER SHOULD BE USED ON ALL HARDWARE.
INSTALLATION:
1. DISCONNECT THE NEGATIVE BATTERY CABLE.
2. USING THE PHILLIPS SCREWDRIVER, REMOVE THE TWO SCREWS HOLDING THE FRONT COVER TO THE HEADLIGHT HOUSING, AND
THEN DISCONNECT THE HEADLIGHT AND SET IT ASIDE.
3. DISCONNECT THE TURN SIGNALS FROM INSIDE THE HEADLIGHT HOUSING, NOTING AS TO WHICH ONE IS THE LEFT AND RIGHT TURN
SIGNAL.
4. REMOVE THE OEM LIGHT BAR USING A 6MM ALLEN WRENCH TO REMOVE THE TWO SOCKET HEAD CAP SCREWS HOLDING IT INTO
THE FRONT OF THE TRIPLE TREE.
5. REMOVE THE TURN SIGNALS FROM THE LIGHT BAR BY USING THE 8MM AND 10MM WRENCHES TO REMOVE THE NUT AND BOLT ON
THE BACK OF THE TURN SIGNAL, THEN PULL THE TURN SIGNAL AND THE WIRES OUT OF THE LIGHT BAR.
6. USING THE 12MM SOCKET WRENCH AND 6MM ALLEN WRENCH, REMOVE THE TWO NUTS AND BOLTS HOLDING THE HEADLIGHT
BRACKET TO THE TOP OF THE TRIPLE TREE, AND SLIDE THE NEW LIGHT BAR BRACKET BETWEEN THE TOP OF THE TRIPLE TREE AND
UNDER THE HEADLIGHT BRACKET. REINSTALL THE NUTS AND BOLTS JUST REMOVED AND TIGHTEN DOWN.
7. 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 8,9,10, AND 12 ARE FOR INSTALLING OEM TURN SIGNALS WITH 62-112T ADAPTERS.
8. INSTALL EACH OEM TURN SIGNAL (G) ONTO THE NEW TURN SIGNAL ADAPTER (H) ROUTING THE WIRES THROUGH THE HOLE IN THE
ADAPTERS. USING THE BOLTS REMOVED IN STEP 6, SECURE THE TURN SIGNAL TO THE ADAPTER.
9. 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.
10. 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.
11. 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.
12. RE-ROUTE THE OEM TURN SIGNAL WIRES INTO THE HEADLIGHT HOUSING AND RE-CONNECT AS THEY WERE.
13. 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 THE 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 THE 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.
INSTALLATION INSTRUCTIONS
PART NO. 63-622
ELLIPTICAL DRIVING KIT
YAMAHA VSTAR1100 CLASSIC/CUSTOM
Revised 10/19/09
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.
