Firstly, check that you have everything in the kit…
Mine was missing the diagram…..But I managed without it!
You should have:
2 Pucks
2 Puck Mounts
1 Spacer
2 Puck Bolts, 1 long, one short
2 Bracket Bolts, with washers
2 Brackets
1 Through Bar
Next thing to do is to remove your upper, and lower fairings…
At the front of the engine, you should be able to see the oil cooler mounts, just under where the front header pipes bolt on to the engine. They are made of aluminium, and are probably covered in white oxidisation and road crud.
The threads in these need to be cleaned before you’ll be able to screw the bolts in. As Dave G has mentioned, the easiest way to do this (If you haven’t got a Metric Fine Tread Tap handy) is to cut slots in the bolts that came with the kit. This can be done with a dremmel, or, as I did, with a hacksaw.
You then need to wind the bolts in, a little at a time, and then wind them out, clean out the crud, and wind them back in again, keep repeating this until the threads are clean, and the bolts can be screwed all the way in.
Next, Insert the left hand side bracket as shown in the picture, and insert the bolt.
This is where I differ from the instructions provided from R&G. I found this easier as access to the space between the 2 brackets is limited…..
From the Right hand side of the bike, insert the long stainless steel through bar, and attach it to the left hand bracket, do this bolt up finger tight. This will hold the bar in place while you install the right hand bracket, and fairing. I found that if you install both brackets, then the bar cannot be lifted in to the correct position as there are radiators and header pipes in the way!
Then, on the right hand side of the bike, fit the brackets as detailed above.
Now fit the right hand fairing.
And screw in the puck mount, Note, the right hand side does not need the spacer, and uses the shorter bolt.
Tighten this bolt up finger tight, Next, remove the puck mount on the left hand side of the bike, The puck mount on the right hand side should now hold the through bar in position.
Install the left hand fairing
And then attach the puck mount, using the longer bolt and spacer.
The 2 puck mount bolts can now be tightening up.
All that’s left now is to finish installing the fairings, and screw in the pucks themselves, then stand back and admire your handiwork while having a beer…..!
The Author: Viffer106 on 400greybike where you can find follow ups to this:
http://www.400greybike.co.uk/Forum/topic.asp?TOPIC_ID=42120&whichpage=1
