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Old 11-17-2006, 06:42 PM
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Default 999R headlight unit removal.

A buddy of mine is working on pulling the headlight bucket out of the 999R and putting in a Vortex fairing stay. Got any advise on how to make it simple? Is it possible to pull the bucket w/ the lights and everything still intact or does he have to split the halves and dismantle everything? The biggest thing he sees off hand is the fuse box... There's no mounting point on the Vortex bracket and he's not sure out to disconnect the wires from it. Any suggestions or ideas would be cool.
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Old 11-17-2006, 07:01 PM
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Removal...

1. Remove mirrors, head fairing, mirror supports.
2. Remove gauge assembly and disconnect wire connector from rear of gauge unit.
3. Unbolt bucket from steering head and twist it upside down as much as possible (while harness still attached to the bike...there is a bit of slack there but not much ) to expose forward harness entry into bucket. Tie off bucket to bars or clamp with tie wire to limit the balancing act..... Remove bottom black plastic cover on bucket...3-4 allen bolts
4. Reach into wire entry and disconnect beams (high/low), air sensor and physically unbolt (allen key) fuse box from interior of the bucket.
5. Carefully remove harness out of bucket.

Note: There are a number of connectors...ensure they are all disconnected and labelled appropriately....it saves a headache when re-installing. It is always best to take a couple of digital pics to note connectors and routing.

As for the fuse box see if it can be taken back and tie wrapped to the small crossers in the frame near the steering head ...if not, he may have to be somewhat creative.....
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Old 11-17-2006, 08:09 PM
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Thanks much!!!
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Old 11-17-2006, 08:32 PM
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A picture is worth a thousand words! Besides my vocabulary isn't that expansive! So here's some Photos.

http://www.hyperpastabiker.net/desmo...0Gen%20020.jpg

http://www.hyperpastabiker.net/desmo...0Gen%20013.jpg

Huge pictures files, but you will have some Photographic detail!
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