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AB0036
R&G
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
Tel: +44 (0)1420 89007 Fax: +44 (0)1420 87301
Email:
FITTING INSTRUCTIONS
•
To begin, loosely assemble both sides of the crash bar expander assembly on the rear
mount of each crash bar as seen in assembly diagrams 1 and 2 (pages 2 and 3).
•
Stretch 2 ‘O’ Rings over the expanders and make sure they sit snugly in the grooves of the
expander.
•
Ensure that the expander nut (Item 5) is fit securely into the recess of the expander (item
4) with the tapered face facing into the expander. Gently tighten so the expander nut grips
the insert, without enlarging the insert, this will ensure that later, when turning the bolt, it
will tighten correctly.
•
Starting from the LHS of the bike, remove the cover cap from the frame below the seat, this
should pop out with a small amount of pressure from a small bladed screwdriver as seen in
picture 1.
•
Remove the upper engine support Torx bolt from the frame using a T45 Torx head tool as
shown in picture 2. DO NOT REMOVE BOTH SIDES AT THE SAME TIME.
•
Offer up the LHS bar assembly to the bike as shown in picture 3, ensuring the expander sits
neatly in the frame tube as seen in picture 4. Be careful to make sure the lower bar does
not contact the exhaust when fitting.
•
While holding the crash bar assembly in position, pass one M10 Hex bolt (item 9) through
the M10 Washer (item 10), crash bar (item 1) and S1160 Spacer (item 6) with the larger
end facing outwards from the bike, and into the frame as shown in picture 5.
•
Loosely fix the bolt to hold the bar in place but do not fully tighten this yet as adjustments
can be made to the bar position later.
•
Connect the connector bar (item 3) to this assembly by passing one end between the
exhaust and engine and into the exposed end of the LHS crash bar. Rotate the bar and
secure in place using the 20mm button head (item 11) bolt as shown in picture 6. It is
recommended that you use a small amount of Loctite on the threads to secure the bolt.
•
Repeat the initial steps for the RHS crash bar. When offering up the crash bar assembly
make sure to pass the end of the lower bar over the connector bar of the bike as seen in
picture 7. And secure the expander and top mounts in the same way as before using the
remaining fitting items as in picture 8.
•
Insert the final M6 X 20mm button head bolt (item 11) to through the RHS engine bar and
into the central connector bar (item 3) using a small amount of Loctite as before.
•
Adjust the adventure bars on the slotted mounts to give the maximum clearance available
between the engine and exhaust, as shown in picture 9. Do this for both sides and inspect
thoroughly before proceeding.
•
Tighten both upper bolts to the correct torque as shown in picture 10 using your 17mm
socket.
•
Ensuring the expander is fully inserted into the frame tube, carefully tighten the bolt to the
point which the insert cannot move, as shown in picture 11. The frame insert will expand
internally with the O-rings gripping the inside of the frame boss
.
DO NOT OVERTIGHTEN AS
THIS MAY CAUSE DAMAGE TO PAINT INSIDE THE FRAME TUBE.
•
Fully tighten the lower connecter bar bolts with the specified torque using a 4mm allen key.
•
Place the M10 hex rubber cap (item 13) over the head of the bolt as shown in picture 12
