ENG 10/02 Fitting Instructions ECE type-approved 1 Component overview 2 Warnings 3 Assembling 4 Light bulb replacement Info: www.kellermann-online.com Dear customer, Thank you for purchasing the BL_1000. We have taken the greatest possible care in the development and manufacturing of this product. We hope you ll enjoy riding with the BL_1000 and therefore you should consider several important instructions. Please read these fitting instructions thouroughly and carefully. If you are not sure how to attach the indicators, or the electrical connections, please take them to your local dealer for fitting. Please bear in mind that only correct installation will ensure trouble free service. We wish you a pleasant and safe journey at all times! Your Kellermann Team 1
1 Component Overview 1 2 5 10 3 4 6 7 8 9 1 Indicator casing 2 Socket 3 Halogen light bulb 4 Multifunction part with key surfaces 5 Hose ring 6 Spacer disk 7 Rubber mount 8 Chassis contact 9 Nut 10 Connecting cable 2 Warnings It is absolutely essential to consider these instructions! Attention! Before fitting please read the fitting instructions! Always adhere to the fitting instructions! Keep the instruction manual, the packaging and spare adapter sets. Attention! Use the BL_1000 only as a front indicator within the EU and follow the instructions for the position according to fig. 3.1. Attention! If you are not sure how to attach the indicators, or the electrical connections, please take them to your local dealer for fitting. Only correct installallation will ensure trouble free service. An incorrect installation will lead to the loss of the vehicle s operating approval, as well as the loss of insurance covery. It also increases the hazard of accidents. Always check before peparting on a journey that your indicators and lights are working, and that nothing has come loose. Should this be the case, refasten and realign the indicators accordingly. 2
Attention! The BL_1000 has exclusively been designed as an indicator for motorcycles and this type is not suitable for other purposes. A different use other than the one predetermined is not permitted. It can be dangerous and lead to substantial damages or accidents. Attention! Only use original spare parts. Especially the light bulbs should only be exchanged for light bulbs of the same specification (H21W, BAY9S, see chapter 4)! This is essential for the appropriate and secure function of the indicator. In case of loss or damage, spare parts, including the special light bulb, are available in trade or directly through the Kellermann company (0049 241 93 80 830). Attention! For your security we have chosen a high performance halogen lamp. Thus, the BL_1000 might heat up during longer periods of operation (more than 10 minutes). Therefore, it is imperative that contact with the skin or with other heat sensitive objects is prevented. Otherwise, injury or damage could occur. 3 Assembling 3.1 Preparations The BL_1000 has been designed for handlebars which are hollow from the end up to at least the respective switch unit and which have a constant internal diameter between 0,47" and 1". Observe the assembling position shown in fig. 3.1. If these prerequisite conditions can not be met, a suitable handle bar needs to be fitted. Attention! Before fitting the indicator, clean the inside of the handle bar tube. Only a clean and grease-free surface will ensure reliable assembling of the indicator. 3
side view driving direction rear view horizontal alignment angle range view from above fig. 3.1 driving direction 4
Attention! Make sure that the motorcycle is on its main stand and is safe before attempting to install the indicators. Failure to do this may cause the motorcycle to fall with possible damage to the motorcycle, fittings or personal injury. Attention! While fitting the indicator, wear work gloves and protective goggles to prevent injuries by sharp edges, e.g. on the handle bar tube or pointed objects such as the chassis contact (8). 3.2 Selection of the adaptor Measure the internal diameter of the handle bar tube. Use the following adaptors for the respective internal diameters: 11.5 mm to 15 mm Adaptor type 1 17 mm to 21 mm Adaptor type 2 (already fitted) 21 mm to 24 mm Adaptor type 3 If you need the adaptor type 1, detach the nut with the earth cable (9), the rubber mount (7) with spacer disk (6) and the hose ring (5) (see chap. 1 Component Overview). Fit the parts of the adaptor type 1 in the following order: Spacer disk, rubber mount, 3 chassis contacts and the nut with the toothed side facing the rubber mount. If you need the adaptor type 2, detach the same components as for the adaptor type 1. First fit the hose ring, then the spacer disk, rubber mount and the nut with the earth cable of adapter type 3 with the toothed side facing the rubber mount. If you need the adaptor type 3, it is not necessary to change anything. The fitting order of adaptor parts is also shown in the component overview (chap. 1). 5
3.3 Fitting the Indicator Attention! Before pushing the indicator into the end of the handle bar, make absolutely sure that the multifunction part (4) is firmly screwed onto the indicator casing. If this is not the case, use a 10 mm spanner to tighten the multifunction part. Loose screw attachment between the multifunction part and the indicator casing can lead to a loss of the indicator casing while riding and might cause an accident. In order to make the connection to the indicator system of your vehicle it is necessary to lead the cable of the BL_1000 out of the handle bar, directly behind the switch unit on each side. Thread a wire (e.g. horticultural binding wire) from the outside to the respective handle bar end and use it to draw the cables through the steering bar. Install the cables with sufficient slack to ensure that the cable will not be under tension even when the handle bar is turned to the maximum. Now carefully push the indicator into the handle bar up to the centre of the rubber mount (see fig. 3.2). Firmly hold the rubber mount and turn the indicator casing clockwise until the rubber mount has risen to such an extent that it lies against the entire circumference of the handle bar tube. Then push the indicator into the steering bar up to the indicator casing and turn the indicator casing by hand, clockwise, until it is ensured that considerable force is required to loosen it again. If after several rotations the needed force does not increase, pull the indicator out again until the rubber mount is half-way out. Turn it counter-clockwise until the cable is no longer twisted and then repeat the fitting procedure as 6 fig. 3.2
described above. Then turn the indicator clockwise so that the glass marked "F" (front) is facing the front and the glass marked "R" (rear) is facing the rear. It is advisable to turn off the motorcycle and disconnect the battery. To connect both BL_1000 to the indicator system of your vehicle, you must connect the cables coming out of the threaded pipes to the plus line of the corresponding front indicator and the cables from the nuts to the minus line. If you have to use adaptor type 1, an electrical connection between the handlebar and the chassis might be needed. The standard chassis connection might be missing with either rubberfitted or anodized aluminum handlebars. If this is the case, the handle bar tube must be connected to the fork bridge by using an additional cable in order to bypass the insulation. In addition, if the handle bar tube is anodized aluminum, it is necessary to remove the internal anodized layer in those areas of the handle bar tube where the chassis contacts of the indicator touch the internal surface in order to create a conducting surface. Reconnect the motorcycle battery. 3.4 Functional test and alignment Attention! Proper alignment of the BL_1000 is necessary for the safety in road traffic and is part of the approval. An incorrect aligned indicator will lead to the loss of the vehicle s operating approval, as well as the loss of insurance coverage. It also increases the hazard of accidents. A B A = B When both indicators have been fitted, test them to make sure that they are functioning properly. If an indicator is not working correctly, check if it is connected correctly or if the light bulb is fig. 3.3 7
defective (see chap. 4). If you use adaptor type 1, check whether the indicator is electrically connected to the vehicle chassis via the handle bar. Establish this connection if it is missing (see chap. 3.3). To align the indicators, place the motorcycle on a hard flat ground with upright straight front wheel directly facing a light coloured wall in a way so that the vehicle axis is perpendicular to the wall (see fig. 3.3). Hold the motorcycle exactly vertically without loading it. Do not rest it on the main or side stand; this would falsify the alignment. Measure (if necessary with the help of a second person) the distance A between the centre of the indicator glass and the ground. Make a clearly visible mark on the wall at the same height. Then turn both indicator casings so that the mark on the wall in each case lies in the centre of the illuminated area. Check again that on both indicators the glass with the letter F and the ECE approval symbol is showing towards the front. The indicators are aligned properly if this is the case. Finally check that both indicators are working correctly. Finally disassemble the previous front indicators. 4 Light bulb replacement 4.1 Preparations Attention! Make sure that the motorcycle is standing on its main stand and is safe before attempting to replace a bulb. Failure to do this may cause the motorcycle to fall with possible damage to the motorcycle, fittings or personl injury. Attention! When fitting the indicator, wear work gloves and protective goggles to prevent injuries by sharp edges, e.g. on the handle bar tube, or pointed objects such as the chassis contact. Make sure that the replacement light bulb has the correct specifications. Exchange the old light bulb only with a new one having the same specification (H21W, BAY9s). These special light bulbs are available in trade or directly through the Kellermann company (tel.: 00 49-241- 93 80 830). 8
4.2 Dismantling the indicator Turn the indicator casing counter-clockwise until it loosens. Then pull the indicator out of the handle bar. After a long time the rubber mount may have bonded to the steering bar, so that loosening the rubber might require additional force and then takes place suddenly. Therefore make sure that the motorcycle is standing securely and that you do not tear off the cable. Apply a 10 mm spanner to the key surfaces (flattenings) of the multifunction part (4) and use it to loosen the screw joint between multifunction part and indicator casing. Should you have problems loosening the multifunction part, try wearing rubber gloves (household gloves) while holding the BL_1000 casing. This achieves greater traction. Then unscrew the indicator casing from the multifunction part by hand. While doing this, make sure that the indicator casing is pointed towards the floor because the socket and the light bulb are only pushed in and may drop out of it. Take the socket and the light bulb out of the indicator casing. A light jolt with the open side on the palm of your hand is sufficient to release the socket. Take out the socket and the light bulb. Do not try to turn the socket because it is fixed by a rotation blocking device in the indicator casing in order to ensure exact alignment of the light bulb. 4.3 Assembly of the indicator and fitting onto the motorcycle Now take the new light bulb and push it from the side with the retaining grooves through the socket. Turn the light bulb so that both retaining pins of the light base sink into the retaining grooves of the socket. Do not touch the bulb with bare hands, as greasy residues on the glass diminish the lifespan of the light bulb drastically. Wipe-off accidental fingerprints on the glass bulb with a fig. 4.1 9
clean cloth/tissue. Now pick up the indicator casing and hold it with the threaded opening facing upwards. (see fig. 4.1). Turn the socket with the light bulb so that the two locating ridges (blue in the illustration) of the socket can slide through between the half-moon shaped contact surfaces (red in the illustration) visible in the indicator casing. Let the socket with the light bulb slide down into the threaded hole. Now pick up the multifunction part (4) and carefully screw the indicator casing onto it by hand. If the multifunction part cannot be screwed-in, the socket is not aligned precisely in the indicator casing. In this case, realign the socket and light bulb. Again screw the indicator casing onto the multifunction part as described above. When the threaded plate is flush with the indicator casing, apply a 10 mm spanner to the key surfaces of the multifunction part and tighten it. Then push the indicator again into the handle bar up halfway to the rubber mount and continue as described in chap. 3.4. Finally, do not forget to align the indicator correctly. www.kellermann-online.com up-to-date Information New Products fiting examples current fiting manuals (download) ECE type approval (download) up-to-date spare parts supplies 10
Now on the Internet Spare Parts Supplies indicator casings in exchange More information available: www.kellermann-online.com 11
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