N928 Installation Instructions
Contents
1. Visor N9005 Alternate Thumb Switch N9001 ADJUSTMENT 1 HORIZONTAL AIM A To adjust the Spotlights or Turnsignals right or left gently rotate the lamp into the correct position In the event that the lamps become loose refer to the procedure for vertical adjust ment 2 VERTICAL AIM FN A Disconnect wire connections inside the Headlight Shell B Pull the wires out of the Light Bar tube C Turn the Turn signal to provide access to the mounting To adjust vertical aim you will need these additional screws tools D Unscrew the Turn signal mounting screws and remove the Hex Key 5 32 or 4mm Turnsignal Hex Key Deep Socket and Socket E Push the Spotlight wire up into the Spotlight Shell 9 16 14mm or a 9 16 F Loosen the nut on the Spotlight stud Deep Socket Slotted Socket G Now adjust the Spotlight Reconnect the spotlight wire and illuminate to verify its projection H Push wire into the Spotlight Shell Firmly retighten the nut on the Spotlight stud Installing optional N9005 Light Head Visor J Pull the wire out of the Spotlight Shell 1 Loosen the rim of the light head assembly Phillips Screw Driver 2 Slip taps of Visor under rim Item E 3 Shape Visor Visor Tabs to conform to contours of light head assembly 4 Retighten rim K Reassemble in reverse order of disassembly L Adjust the Spotlights and Turn signals horizontally by rotat ing into position M Verify2. nal Turn on bike and check The two short BLACK wires are for the running lights One BLACK wire for the Left side running light and one for the Right side running light Turn on bike and check The Light Bar attached to the front fork of the motorcycle serves as the ground in most cases A precautionary step to insure proper grounding is to take one of the Green Ground wires from the existing turn signals and ground that between the Light Bar Mount and the Triple Tree Bracket Always start by doing one side at a time Preferably the right side or high side of the bike first 10 110728 000 Rev A 04 02 WARNING REPLACEMENT PARTS and ACCESSORIES After wiring the light bar check for clearance Make sure Order parts through your local dealer or contact National Cycle the wires can not get pinched when the fork is turned to a n N928 N928E full fork lock left and right Description Part No Part No Check all lights for proper operation Light Head Assembly 90 910501 000 90 910501 000 Lamp Assembly E13 DOT PAA ate ep that have been Reflector Lens and Bulb 90 901011 000 90 901011 000 Turn Signal Assembly 90 930921 000 90 930921 000 MAINTENANCE Turn Signal Lens 90 930213 000 90 930213 000 The high quality chrome finish of your National Cycle light bar can be maintained with any quality chrome cleaner and Turn Signal Bulb Only Bulb 1157 Available at Most Auto Parts Stores or polish Light Bar Accessories Chrome Viso
3. operation of the lights Page 4 of 4 10 110728 000 Rev A 04 02 04 02 2001 National Cycle Inc PO Box 158 Maywood IL 60153 0158 USA 708 343 0400 Fax 708 343 0625 www nationalcycle com e mail info nationalcycle com
4. the lights Page 2 of 4 10 110728 000 Rev A 04 02 2001 National Cycle Inc PO Box 158 Maywood IL 60153 0158 USA 708 343 0400 Fax 708 343 0625 www nationalcycle com e mail info nationalcycle com national cycle PARTS LIST Description Qty 1 6 Lightbar Assembly N928 or N928E Connectors Scotchlok PREPARATION 1 Make certain the motorcycle is securely positioned for this installation Cover the front fender with a protective cloth to avoid scratches 2 Remove Headlight from Headlight Shell Screwdriver Set aside 3 Unplug Turn signal wires and pull them out of the Headlight Shell 4 Loosen clamping screws on Turn signal mounting clamps Hex Key 5mm 5 Remove Upper Triple Clamp Refer to Service Manual 6 Slide Turnsignals up fork tubes and remove Set aside they will not be reused 7 Reinstall Upper Triple Clamp per Service Manual INSTALLATION 1 Mount the Light Bar Assembly A Cover the front fender to protect it from damage B Remove the nuts from the Headlight Shell mounting screws 10mm Socket set aside Let the Horn hang from its wires C Lift the Headlight Shell until the mounting screws are removed from the lower Triple Clamp D Hold the Light Bar assembly in place on the lower Triple Clamp and reinstall the Headlight Shell and Horn Tighten the nuts to manufacturer s specified torque 2 Wire the Light Bar Assembly A Route the Light Bar Assembly wires over the lowe
5. gnal Right Short Red Black Running Light Left Short Black Grey Short Black Grey White High Beam Black White Running Light Right Passing Lamps Long Blue Ground 11 Reinstall the headlight and rim NOTE Check local regulations for proper passing lamp operation Some states require passing lamps be lit only with hi beam Page 1 of 4 INSTALLATION AND OWNER S MANUAL N928 or N928E European LIGHT BAR for Suzuki VS800 Intruder Pages 1 and 2 Suzuki VZ800 Marauder Pages 3 and 4 mu Screwdriver 2 Phillips Hex Key 5mm 2 Socket 10mm and Ratchet Wrench TOOCEBOX Pliers Slip Joint Plus tools required for removal of Upper Triple Clamp NOTE this installation for the VS800 Intruder requires removal and reinstallation of the upper Triple Clamp Refer to your Service Manual for the proper tools and procedure NOTE right and left on the motorcycle are determined from the rider s position Position light bar assembly between the lower triple clamp and the head light shell mounting bracket Note Light Bar Wiring Helpful Hints The long Blue wire is the main power wire for the spotlights on the light bar Connect that to the main power source from the headlight Either the High Beam wire or the Low Beam wire The choice is your preference Turn on bike and Check The two short RED wires are for the turn signals One RED wire for the Left side turn signal and one for the Right side turn sig
6. kkk m Pa national cycle Description Qty Lightbar Assembly N928 or N928E 1 Connectors Scotchlok 6 PREPARATION 1 Make certain the motorcycle is securely positioned for this installation Cover the front fender with a protective cloth to avoid scratches 2 Remove Headlight from Headlight Shell Screwdriver Set aside 3 Unplug Turn signal wires and pull them out of the Headlight Shell 4 Loosen clamping screws on Turn signal mounting clamps Hex Key 5mm 5 Remove Upper Triple Clamp Refer to Service Manual 6 Slide Turnsignals up fork tubes and remove Set aside they will not be reused 7 Reinstall Upper Triple Clamp per Service Manual INSTALLATION 1 Mount the Light Bar Assembly A Cover the front fender to protect it from damage B Remove the nuts from the Headlight Shell mounting screws 10mm Socket set aside Let the Horn hang from its wires C Lift the Headlight Shell until the mounting screws are removed from the lower Triple Clamp D Hold the Light Bar assembly in place on the lower Triple Clamp and reinstall the Headlight Shell and Horn Tighten the nuts to manufacturer s specified torque 2 Wire the Light Bar Assembly A Route the Light Bar Assembly wires over the lower TripleClamp and into the Headlight Shell B Attach the Light Bar Assembly wires per the following st NOTE Grounding is through the frame Light Bar Motorcycle Turnsignal Left Short Red Light Green Turnsi
7. ort BLACK wires are for the running lights One BLACK wire for the Left side running light and one for the Right side running light Turn on bike and check The Light Bar attached to the front fork of the motorcycle serves as the ground in most cases A precautionary step to insure proper grounding is to take one of the Green Ground wires from the existing turn signals and ground that between the Light Bar Mount and the Triple Tree Bracket Always start by doing one side at a time Preferably the right side or high side of the bike first 10 110728 000 Rev A 04 02 A WARNING After wiring the light bar check for clearance Make sure REPLACEMENT PARTS and ACCESSORIES Order parts through your local dealer or contact National Cycle the wires can not get pinched when the fork is turned to a N928 N928E full fork lock left and right Description Part No Part No Check all lights for proper operation Light Head Assembly 90 910501 000 90 910501 000 Check the tightness of all fasterners that have been Lamp Assembly E13 DOT involved in this installation Reflector Lens and Bulb 90 901011 000 90 901011 000 Turn Signal MAINTENANCE Assembly 90 930921 000 90 930921 000 The high quality chrome finish of your National Cycle light Tum Signal Lens 90 930213 000 90 930213 000 bar can be maintained with any quality chrome cleaner and Turn Signal Bulb Only Bulb 1157 Available at Most Auto Parts Stores or polish Light Bar Accessories Chrome
8. r TripleClamp and into the Headlight Shell B Attach the Light Bar Assembly wires per the following list NOTE Grounding is through the frame Light Bar Motorcycle Turnsignal Left Short Red Light Green Turnsignal Right Short Red Black Running Light Left Short Black Grey Short Black Grey White High Beam Black White Running Light Right Passing Lamps Long Blue Ground 11 Reinstall the headlight and rim NOTE Check local regulations for proper passing lamp operation Some states require passing lamps be lit only with hi beam Page 3 of 4 INSTALLATION AND OWNER S MANUAL N928 or N928E European LIGHT BAR for Suzuki VZ800 Marauder Pages 3 and 4 mu Screwdriver 2 Phillips Screwdriver 3 Phillips i Socket 10mm and Ratchet Wrench Pliers Slip Joint NOTE right and left on the motorcycle are determined from the rider s position TOOLBOX Position light bar assembly between the lower triple clamp and the head light shell mounting bracket Note Light Bar Wiring Helpful Hints The long Blue wire is the main power wire for the spotlights on the light bar Connect that to the main power source from the headlight Either the High Beam wire or the Low Beam wire The choice is your preference Turn on bike and Check The two short RED wires are for the turn signals One RED wire for the Left side turn signal and one for the Right side turn sig nal Turn on bike and check The two sh
9. r N9005 Alternate Thumb Switch N9001 ADJUSTMENT 1 HORIZONTAL AIM A To adjust the Spotlights or Turnsignals right or left gently rotate the lamp into the correct position In the event that the lamps become loose refer to the procedure for vertical adjust ment 2 VERTICAL AIM E A Disconnect wire connections inside the Headlight Shell B Pull the wires out of the Light Bar tube C Turn the Turn signal to provide access to the mounting screws D Unscrew the Turn signal mounting screws and remove the Hex Key 5 32 or 4mm Turnsignal Hex Key Deep Socket and Socket E Push the Spotlight wire up into the Spotlight Shell 9 16 14mm or a 9 16 F Loosen the nut on the Spotlight stud Deep Socket Slotted Socket G Now adjust the Spotlight Reconnect the spotlight wire and illuminate to verify its projection H Push wire into the Spotlight Shell l Firmly retighten the nut on the Spotlight stud Installing optional N9005 Light Head Visor J Pull the wire out of the Spotlight Shell 1 Loosen the rim of the light head assembly Phillips Screw Driver 2 Slip taps of Visor under rim Item E 3 Shape Visor Visor Tabs to conform to contours of light head assembly 4 Retighten rim To adjust vertical aim you will need these additional tools K Reassemble in reverse order of disassembly L Adjust the Spotlights and Turn signals horizontally by rotat ing into position M Verify operation of
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