Fitting instructions for Lynx R Fairing - KTM 690

Transcription

1 Fitting instructions for Lynx R Fairing - KTM 690 Thank you for purchasing the Lynx R fairing. Your fairing kit comes largely completed, with most of the fitting time involved with the attachment of your instruments. 1 x Fairing 1x Screen 2x 35mm thumbscrews threaded into two plastic sliders and Nylock nuts. 2x 16mm M6 screws 3x 30mm M6 screws 2 x plastic washers 2x M6 Flange Nuts 4x aluminum dashboard spacers 4 x SS washers 1 x Aluminum bottom bracket with threaded bolt, washer and Nylock nut 1 x ABS Dash. 1 x Wiring Harness Decal pack Fitting Secure the Motorcycle in a vertical position. Remove the seat Remove OEM fairing and disconnect OEM light terminals at the white terminal block. Unplug the speedo terminal and remove your OEM instrument unit from it s mounting. You will be re-using the screws to attach the instrument to the new Lynx R Dashboard. Example shown is the 09 on model. Remove the front fender IMPORTANT By far the most important part of your installation is the fitment of your instruments. There are many different configurations open to you to customize your instrumentation as you see fit, which includes switches, warning lights, accessory power sockets, gauges and GPS s. Most important of all is the old Carpenters saying Measure twice and cut once You will need to decide where you wish to locate the speedo on the Lynx dash. Generally, you need to mount it low so that you have space for a GPS or other instrument. Also make sure that there is enough cable to reach the speedo in your desired position.

2 NOTE : Before deciding on the final position of the speedo, check from the riding position that your view of the speedo is not hindered by the front Brake line and adjust the position accordingly. Normally you can position the speedo so the line passes above your view point, but below where you would place the GPS. You can use the rubber speedo mounting washers from the speedo and drill the dash to the same pattern as the OEM speedo mount.!! Fitting the Fairing and Dash The dashboard locates onto the 3 threaded holes on the front face of the top triple clamp also used by the OEM speedo mount and indicator bracket ( on some models) Unbolt the OEM speedo/indicator bracket and the plastic backing divider. Fit the dash and the indicator bracket ( if applicable) in the following order from the front face of the top triple clamp and refer to the photos. You will see that you need to add two spacers (provided) to the two outer holes on each side of the dashboard to make a flat surface.!

3 !!! Use the 3x 20mm button head bolts to secure the dash along with the Speedo/ indicator bracket and plastic divider in front on the centre hole Do not be concerned that the dash does not appear rigid at this stage because it all stiffens up when the fairing is attached. Re-attach the speedo to the harness. The front brake cable fits into the keyhole on the left side of the ABS dashboard. Indicator fitment on models that have them located on the OEM fairing If your model has the indicators mounted to the OEM fairing, the best way to relocate them is to obtain KTM OEM part # called flasher bracket. If you do not want to get this part, then you can relocate the indicators onto the fairing attaching them to the wings of the dashboard. You will need to drill the appropriate holes as shown Wiring Harness for the lights Your wiring harness comes largely complete and we have deliberately not mounted the relay to the back of the dash to allow you placement options for your own instrumentation. The relay operates the HID low beam and receives it s power directly from the battery. The LED High beam draws it s power from the bikes OEM Hi beam source.

4 You will see that there are separately fused power wires included in the harness that can be used for powering accessories such as GPS, heated grips and power sockets. One of these is switched through the ignition, the other is direct power from the battery and remains live at all times. First of all, run the power and ground wires back to the battery on the left side of the frame alongside the clutch cable to start with and strap it up neatly. Connect the power wire to the positive post and the ground to the negative. After making sure that you know where your instruments/accessories will be mounted, find a clear area on the back of the dash to locate the Relay. Make sure that you have enough reach from the relay to where the lights are positioned when the fairing is fitted ( i.e., not too high on the back of the dash) and that the steering will sweep from side to side without hindering any of your wiring. We have added a Hitachi style white plastic terminal block that plugs straight into the headlight terminal you unplugged earlier and controls the Lynx wiring harness. Fitting the bottom bracket The aluminum bottom bracket fits between the front fender and the underside of the bottom triple and clamps up using the OEM fender bolts ( see pic), but first you will see that the fender needs to be trimmed to allow the bracket to seat properly and allow room for the flange of the fairing.!! When you have the fender and bracket sitting together, place 2 aluminum washers as spacers on each of the back bolts ( to level the fender) and tighten all 4 bolts. Attaching the screen Attach the screen with the two thumbscrews threaded into the two black plastic sliders that run in the channel on the back of the fairing. Tighten the thumbscrews up until the sliders just touch the back of the fairing and the screen can still slide up and down freely. Then thread the two Nylock nuts onto the extended thread until they just touch the back of the sliders. These act as a backstop to stop the thumbscrews being able to undo too far and allowing the screen to come out of the tracks. If set correctly, you should only need one turn on the thumbscrews to tighten the screen from fully undone.

5 Fitting the Fairing First, make sure that you strap up any loose wires at the back of the dash. Particularly, make sure the steering sweeps cleanly from side to side without pinching or stretching any of the wiring. Rest the fairing on the front fender, attach the light terminals and then slide the bottom of the fairing onto the two captive bolts on the bottom bracket ( The Lynx R uses the top hole positions on the bracket). Then loosely clamp the top of the fairing and dash together using two 16mm button head screws and flange nuts No need to tighten yet, because you may be removing the fairing to adjust the lights. Now turn the ignition on and check the operation of the lights. Adjusting the lights High Beam : The LED is attached to the frame with a bolt on each side ( see photo). To adjust the lamp, you can normally push the top or bottom outer rim of the lamp and it will move a little. You will need a bit of force so DO NOT press on the lens of the lamp.!!! Low Beam : The HID low beam is the most critical to set correctly and it s also the easiest to adjust. The lamp is retained by 3 adjuster screws and you should not need to adjust the top two and just use the bottom one for height adjustment ( see photo). In order to access the bottom adjuster with the fairing on, turn the handlebars to the right and drill an a hole in the plastic backing plate. Make sure you do not drill through any of the wiring on the front face of the panel! Make height adjustments using a Philips screwdriver ( see photos) through the hole you have drilled. Turn CLOCKWISE to lower the beam height, ANTI CLOCKWISE to Raise the beam height.

6 IMPORTANT : If your height adjustment causes either lamp to touch the fairing openings it will cause an annoying vibrating noise and excessive wear. In this case, remove fairing and bring the lamp rearwards using the top and bottom adjusters ( turn adjusters Clockwise) When you are happy with the light adjustment, re-attach the fairing. Place a SS washer before fitting a nylock nut on the rubber grommet at the bottom and do not over tighten so that the grommet can work effectively to reduce vibration. A plastic washer should be fitted under the screw head on the fairing side of the top mount before securing with a flange nut on the dashboard side. Decals Included in the kit is a decal pack containing some different shapes and colours for you to apply if you wish. Application is the same as most decals and is best done by wetting the fairing surface first and then using a squeegy to smooth any air bubbles out. Final Check Make sure that all components are secure and that you have free movement from side to side with the handlebars. Adjusting the screen Operation of the adjustable screen is straightforward. It is designed to slide down completely when off road (if desired) and can be adjusted to suit at highway speeds. Riders over six foot, will almost certainly place it in it s highest position, but experiment with different heights, because highest isn t always best. Do not over tighten the thumbscrews Accessory sockets If you have purchased accessory sockets, installation is straight forward by drilling the appropriate sized hole in the dashboard and fitting the socket, then plug straight into either the constant power or switched power accessory cables on the wiring harness. Note : You may not realise that the twin USB charging socket has a magnetic switch on the cap so that it is off when the cap is in place. It is therefore ideal to have this socket attached to the constant power source because it will not draw any power whilst the cap in on.

7 Manufactured by : Britannia Composites Ltd nd Drive, Langley, BC Canada V2Z 2M9 Tel ; 1 (604)