Instructions for Lynx R Fairing - KTM EXC 500 Husqvarna 501 Thank you for purchasing the Lynx R fairing. The kit includes the following parts : 1 x Fairing and 1x Screen 2x 16mm M6 button head screws 4x 25mm M6 flange bolts 4x Rubber washers 2x 10mm aluminum bottom bracket spacers 2 x plastic washers 2x M6 Flange Nuts 1 x Aluminum bottom bracket with threaded bolt, washer and Nylock nut 1 x ABS Dash. 1 x Wiring Harness Decal pack Fitting Note that the relocation of the indicator flashers will require you source KTM part # 78014033000 EXC flasher bracket shown here : Secure the Motorcycle in a vertical position. Remove the seat Remove OEM fairing mask and disconnect OEM light terminal at the white terminal block, indicator terminals and ignition switch. Unscrew the Speedo instrument holder from the front face of the top triple clamp. Unplug the speedo terminal and unscrew the speedo unit from it s mounting ( see photo). You will be re-using these screws to attach the instrument to the Lynx R dashboard Unplug and remove the small green indicator light from the speedo mount and set aside for relocation onto the Lynx dash later.
Fitting the Dashboard With the speedo set to one side, the speedo mount can now be relocated back to it s OEM position on the front face of the top triple clamp. You will also bolt the Lynx dashboard ( using the outer holes) and the KTM flasher bracket on top of the mount so that everything is secured together onto the front face of the top triple using the two 25mm flange bolts included with the kit as shown. IMPORTANT DASHBOARD LAYOUT INFORMATION With the dashboard installed, the most important part of your installation is the fitment of your instruments and switches etc. There are many different configurations open to you to customise 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
Fitting the OEM Speedo to the Lynx Dashboard 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 instruments. Also make sure that there is enough cable to reach the speedo in your desired position. 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. Use the same hole pattern as the OEM speedo mount to mark out where to drill location holes for the speedo and then mount the speedo using a rubber washer on each side of the dashboard as shown. Plug the terminal back into the Speedo and then secure to the dashboard using the OEM screws you removed earlier. GPS Mounting If mounting a GPS, the best location is above the speedo and the GPS will mount using the makers GPS holder bolted to the surface of the ABS dashboard. Whilst the angle of the dashboard is suited to the rider viewing the instruments from the seated position, many prefer to have the GPS on an adjustable base so that the instrument can be angled and viewed when stood on the pegs. In this instance we recommend using the mount made by SW Motech which remains sturdy both on and off road ( see photo). The GPS holder can be wired into either the switched power accessory terminal, or the constant power accessory terminal ( see section on wiring harness). We do not recommend mounting a RAM arm from the dash surface due to excessive movement in off road conditions.
Fitting the ignition switch and directional indicator light Remove the ignition switch from its position on the OEM headlight unit. You will need to drill a suitable sized hole in the Lynx dashboard to relocate the ignition switch. We recommend using the side of the dashboard on the right side. Re connect the ignition to the wiring harness. Choose a suitable location to mount the green flasher indicator light and drill a hole in the dashboard for it. The hole size should be just big enough for you to be able to push the light into place. Indicator fitment Remove the indicators from the OEM headlight unit and using the same hardware, attach them to the indicator mounting bar you mounted earlier (KTM OEM part # 78014033000 flasher bracket ). Reconnect the indicator terminals to the main wiring.
Explaining the Lynx R Wiring Harness for the lights Your wiring harness comes complete and once plugged in, will be controlled from you OEM lighting circuit. The HID low beam lamp receives it s power directly from the battery via the relay, but the LED High beam lamp draws it s power from the bikes OEM Hi beam source. The reason the two lamps draw their power from different sources is to avoid overloading the OEM wiring circuit when both lamps are lit on High beam and also to help make sure that you always have one lamp working in the event of a major failure of either the Lynx wiring harness, or the bike s own lighting circuit. The small diode that you can see bridging between the High and low beam wires is there to ensure that the low beam remains on when the High beam is switched so you benefit from both lamps. You will also see that there are two, separately fused power circuits designed into the harness that can be used for powering accessories such as GPS, heated grips and power sockets. One of these circuits is switched through the ignition, the other is direct power from the battery and remains live at all times. Fitting the Lynx R wiring harness Loosen the bolts retaining the gas tank, but there is no need to disconnect the fuel supply, or remove the gas tank, but the tank will need to be lifted a little. The wiring harness has positive and negative wires with battery terminals and these need to be run down the left side of the bike, starting by feeding the wires between the forks and triple clamps at the front. Run the wires alongside other cables, under the gas tank and back to the battery area as shown Connect the power wire to the positive post on the battery and the ground to the negative post and then make sure the fuse is tucked away neatly and won t interfere with the seat when it is refitted. When you are happy that the wires are running neatly alongside the other wiring, take care to strap them along the frame with zip ties Replace the gas tank and seat
After making sure that you know where your instruments/accessories will be mounted on the dashboard, find a clear area on the back of the dash to locate the Relay. Make sure that you have enough reach to the relay and that the steering will sweep from side to side without pulling any of your wiring. Plug the white Hitachi terminal into the OEM headlight terminal you unplugged before Fitting power sockets to the dashboard The power sockets we supply are designed to plug straight into the Lynx wiring harness. Choose an appropriate location and use a hole saw to cut the correct sized hole in the dashboard and insert the socket. It is not obvious, but the twin USB socket has a magnetic switch in the cap, so that the small LED light will go out when the cap is on. This means there is no problem with battery drain, if the USB is plugged into the constant power accessory source on the Lynx harness if you choose. When locating the sockets, remember that the sides of the dashboard also make a good placement for the sockets. Fitting the bottom bracket Undo the two bolts that attach the front fender to front face of the bottom triple clamp. The bracket bolts up to the same location using two 25mm flange bolts supplied and two 10mm spacers between the bracket and the fender as shown. 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.
Fitting the Fairing First, make sure that you strap all of the OEM wiring and the Lynx wiring harness 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. The only wires that need to be kept free are the two headlight terminals that you will plug in when the fairing is fitted. Holding 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. 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. Make height adjustments using a Philips screwdriver ( see photo) Turn CLOCKWISE to lower the beam height, ANTI CLOCKWISE to Raise the beam height.
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 Manufactured by : Britannia Composites Ltd 5084 242 nd Drive, Langley, BC Canada V2Z 2M9 Tel ; 1 (604) 612 2170 www.britanniacomposites.com