4
2. Body installation
Mounting the tank
Slip your stock cushions over the rubber studs I
mounted under your tank
Connect fuel lines and in-line filters
Slide the tank on as you would the stock tank. Rear
tank hole fits on frame stud
Connect line to carbs
Tank is installs before the tail
Mounting the tail
Install tail piece and guide on the ½” hole (rear tank
mount post). Trial fit tail. If binding with tank occurs
simply grind away a bit of hole, probably on the
leading edge of the hole. Shim to get a flush fit
between tank and tail
This is tricky – follow closely
A.
With tank and tail on the bike, center the tail.
You’ll notice a small drill point about ½ way
back on top of the tail. Lift the tail off to see
where you are going to drill your mounting
hole.
B.
Reinstall tail. Now drill a 1/16” hole through
the drill point and into frame.
C.
Pop off the tail and look at your drill mark. Is
there enough frame material around the drill
mark for a 25/64” hole? If not make a new
hole with the 1/16” drill.
D.
Pop off the tail again. Ultimately you will
need 25/64” hole. Don’t start drilling with this
big drill. Start the hole with ever increasing
drill sizes up to 25/64.”
E.
Warning
Just below the surface you are drilling
through is another frame piece BUT this
piece is at an angle. If you are not careful,
your drill is going to be deflected. You want a
straight hole for the threaded insert I have
provided you.
F.
You now have a 25/64” hole in your frame
and the tail is on the bench over there.
Threaded insert. Find the nifty little assembly which
is a thread-zert with a 5/16” nut and ¼-20 bolt
holding it all together. Shove the thread-zert into
the frame hole and make sure its flush on the
frame. Hold the 5/16” nut with ½” wrench. Start
tightening the ¼-20 bolt with a 7/16” wrench. What
you are doing is squeezing the thread-zert so it fills
the hole and swells out underneath. This will lock
the threads into the frame. Tighten until the
resistance increases. Overtighten beyond this point
and you’ll distort the threads and you’ll have to
chase them with a ¼-20 bit. This your anchor the
rear of the tail. Save my little tool pieces if the zert
loosens up-you can just crank on it again.
Warning
I suspect the two tail mounting places may not be
strong enough to carry a passenger—so don’t
unless you mount the tail more solidly.
When you mount the tail to the frame use red
Loctite on front and rear bolts. Use Loctite on the
6mm bolt which holds the rear of the tank and front
of the tail in place. Make sure you secure the two
body parts with a washer wider that the hole. I
wouldn’t over tighten either of these two bolts or
you may crack the fiberglass.
These two mounts will hold your tail in place. The
fender is shaped to sit on the frame for weight
support.
The seat cushion mounts with Velcro (supplied)
3. Vinyl graphic installation
You have only two approaches for applying graphics.
They are very difficult to apply. The problem is lining up
long skinny graphics over tank and tail. Do not try it
yourself-it’s just extremely difficult to do it without
misaligning one of the four parts. If you get 3 of the 4
right-what do you do? You’d have to call for another of
the botched vinyl parts.
Option one
-pay me to do it.
Option two
-pay your sign company to do it. You can
bitch at me/them if they screw up.
Summary of Contents for X650
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