GV250 How To: Foglight Install

NOTICE: Bill Ramby and AlternativeCruisers.Com takes no responsibility for any mishap, error or explosion. If you cannot take responsibility for your own actions, please stop now.

I received a set of second hand foglights that were originally purchased from Richard Jordan in South Korea. Installing them was interesting to say the least. As always, I documented the steps I took in the hopes that it might help someone down the road.

Ok, lets get to it!

First off, here's the supplies I gathered:

Foglight Kit
14MM Socket Wrench
10MM Socket Wrench
#3 Phillips Head Screwdriver
#2 Phillips Head Screwdriver
Various Electrical Connectors*
Electrical Connector Crimper*
Electrical Tape
Razor Knife
Dykes (Wire Cutters)
And as always; COFFEE!

* You may not need these, since mine was second hand, I think it may have been missing a wire or two.

First off, get in front of the bike, squat down and locate the two 10MM hex head bolts and two #3 Phillips head bolts.

You will want to remove the back bolts (hex heads) first. The reason is that the front bolts hold the blinker bar and bar cover in place and you don't want it falling in your way while trying to remove the back bolts.

With a 14MM wrench, adjust the light position on the foglight bar where you want it. You need to do this prior to putting the bar in place on the bike because the blinkers will be in the way after it is on.

Tilt the foglight bar and insert it between the forks. You have to tilt it, otherwise it wont fit.

Insert and hand tighten the rear hex head bolts.

Insert the Phillips head bolts and wrench tighten all bolts.

Ok, now we have the chrome pieces mounted.

Connect the power leads of the On/Off switch to the leads on the foglights.

No mounting ground wire came with the lights so I had to make my own. I made two wires with a lug on one end and a female bullet connector (to match the foglight grounding wire) on the other end.

Remove the bottom headlamp bracket bolt. We're going to use this to ground our foglights.

Slip a lug from each wire on each side of the bracket and remount the bolt and nut. It's not easy and the space is tight so take your time. Connect the other end of the ground wires to the bullet connectors on the foglights.

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STOP!

You are at a decision point here. The choice is whether to use the standard switch that comes with the kit, or whether to integrate the switch utilizing the non-working headlamp switch (U.S. models, and maybe some other countries).

To continue with the advanced install utilizing the integrated headlamp switch, please click here.

To continue with the standard install utilizing the switch from the kit, please read on.

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Decide where you want your switch placed.

WARNING: You are about to move the gas tank! No Smoking!

NOTICE: Bill Ramby and AlternativeCruisers.Com take no responsibility for any mishap, error or explosion. If you cannot take responsibility for your own actions, please stop now.

Switch your petcock to the "Off" position as we will be shifting the tank.

Remove the seat and, using a 10MM wrench, remove the two bolts at the base of the gas tank.

Slide the tank toward the rear of the bike until it is clear of the collar and collar clips. On the right side of the bike, using a #2 Phillips head screwdriver, remove the two screws holding the collar in place.

Grab the collar at the bottom and tilt upwards.

Now tilt the collar horizontal (bottom to the rear) and lift off.

You should now see an exposed wiring harness.

With a #3 Phillips head screwdriver, loose the bolt on the chrome case cover below the seat. Remove the plastic piece that sits above it to expose the battery.

Remove the restraining bracket by removing the two bolts holding it in place with either a 10MM wrench or a #3 Phillips head screwdriver.

Slide the battery out about two inches to give yourself room to work.

Run the foglight power lead from the switch, under the tank (just lift the tank on the right side a very little) along the same route as the existing wiring, and coming out just in front of the battery.

Slide the positive terminal boot cover back and loosen the bolt on the terminal using a 10MM wrench (Do not remove the bolt, just loosen it a little). Insert the foglight power lead and re-tighten.

Tuck the extra wire in the open space just in front of the battery and push the batter back in place.

Replace the restraining bracket.

Replace the side cover and tighten the bolt.

Replace the collar.

Slide the tank forward into the clips.

Insert and tighten the bolts at the base of the tank.

Replace the seat.

Thats it. Your done.

Note: This is a direct wire to the battery. If you fail to remember to switch it off when the motor is off, you will drain your battery quickly. I didn't design it this way, so don't yell at me. If you want a better wiring method, please click here.