ETM RTR Headlight Installation Instructions

1. Remove the Crossbar from the handlebars, the Front Number Plate, the Display, and the Display Bracket from the bike.
2. Take off the Seat, and remove the Battery from the bike.  Turn the key ON for a few seconds, then turn back OFF, this will discharge any power still stored in the controller.
3. Install the Display onto the Headlight Mount as shown using the OEM hardware.

4. Install the Headlight Mount onto the bike as shown using the OEM hardware that originally held the Display Bracket.

5. Hold the Rear Brake Line in place using two Cable Holders, two M4 Washers, and two M4x8mm screws.  It is recommended to use blue (medium strength) threadlocker on these fasteners.

Note: The cable holders should be oriented such that the flat side is facing forwards, which will hold the brake line slightly behind the bracket.

6. Route the wiring harness from the Headlight through the opening in the Headlight Bracket, and to the left side of the bike (along the same route as the brake line and other wires).  Continue to run the harness along the path of the Rear Brake Line and Display harness through the opening in the Left Frame Cover.  

Note: It may be helpful to remove the Left Side Panel and Left Frame Cover temporarily to aid in cable routing.

7. Install the Power Switch onto the handlebar in its desired location, then run the wires along the same path as the headlight harness.
8. Loosely install the Headlight onto the Headlight Bracket using the hardware supplied in the Headlight kit.  Only the two socket head screws and square nuts will be used, all other hardware may be discarded.  Keep the Headlight loose for now, the final position will be adjusted later.

9. Reinstall the Front Number Plate using the OEM mounting hardware.

10. Position the headlight at the desired angle, and fully tighten the mounting bolts to lock it in place.
11. We will now move on to mounting the DC-DC inverter to the bike.  First remove the Rear Mud Guard (the rubber Mud Flap will come off with it), as well as the Right Number Plate   
12. Install the DC-DC Mounting Plate to the Rear Subframe as shown using four M6x12mm screws and four M6 Nylock Nuts.

Note: The nuts must be on the top side of the plate as shown

13. Install the Tool Pouch Holder and DC-DC (with wires facing down) as shown using two M6x12mm screws each.  It is recommended to use blue threadlocker on these fasteners.

Note: The DC-DC may be a tight fit.  Ensure that the upper left nut on the mounting plate is oriented parallel with the DC-DC housing as shown for maximum clearance.

14. Below is a basic diagram of the Wiring Harness and the connections that should be made.  

• Plug the Wiring Harness into the male 3-pin connector on the DC-DC, and female 3-pin connector on the Power Switch.
• Plug the Headlight into one of the available 12V accessory plugs on the DC-DC (any of the available 2-pin plugs will work).
• Plug the female XT90 connector on the Wiring Harness into the male XT90 connector attached to the Charge Port (this connector was previously plugged into the battery).
• Leave the battery out of the bike and do not plug in the male XT90 connector for now. 
   

15. Once all connections have been made, secure the wires to the right side of the Subframe and Main Frame using zip ties or velcro straps.  Take your time here and secure the wires such that they cannot rub against any sharp edges on the frame or brackets.

16. If desired, secure the tool kit that came with your bike to the Tool Pouch Holder using two velcro scraps as shown.  This can be handy for quick trailside repairs.

17. Reinstall any plastics that were removed from the bike using the OEM mounting hardware.  Reinstall the battery and plug the male XT90 connector from the Wiring Harness into it, then power the bike on using the keyswitch.  When the Power Switch on the handlebar is turned on the headlight should illuminate.
    
     

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