Automotive Manual PDF

Heli Bars are designed to safely increase your riding comfort; however it is imperative that these instructions be followed to ensure correct installation. Failure to follow these instructions could result in improper installation and create a dangerous control situation. If you have any questions about installation call Heli Modified, Inc. at 1­800­859­4642. This installation requires the use of a torque wrench that covers a torque range of 8 ft. lbs. Before stock bars can be removed, it is necessary to rotate the front brake line clockwise at the master cylinders. Loosen the banjo bolt at the front brake master cylinder just enough so the fitting can be rotated. Position the banjo fitting so the hydraulic line rests against the right fork tube. Cover the fairing with a rag as some hydraulic fluid may leak. Retighten the banjo bolt.
NOTE: If this modification is not performed prior to removing the stock bars, it will not be possible to mount the master cylinders to the Heli Bars.
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Do not smoke or be near open flame while performing installation. Wear eye protection as the fuel system is under pressure.
Kit includes
• Installation bracket, fuel line disconnect tool, and cable/zip ties.
• EFI multi port fuel injection hose and fuel line quick connect fittings.

Installation Procedure
• Screw the 90* fittings into the top and bottom of the Fitch unit. Tighten down the lock nut on the 90* fittings.
• Using the 18” hose with the female plastic fitting, screw the opposite end to the 90* fitting at the top of the Fitch unit and the 6” male hose to the bottom of the Fitch unit.
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Installation instructions:
1) disconnect negative battery cables from both batteries and secure so they can’t touch battery posts.
2) remove positive cable from driver’s side battery.
3) unsnap battery cover from drivers’ side. This is a real pain, sticking a screwdriver in the slot helps.
4) remove battery. Save the battery hold down bolt and block. this will be reused on the ump bracket.
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Heli Bars are designed to safely increase your riding comfort, however it is imperative that these instructions be followed to ensure correct installation. Failure to follow these instructions could result in improper installation and create a dangerous control situation. If you have questions about installation call Heli Modified, Inc. at 1-800-859-4642.

NOTE: Heli Bars for the ST3 and ST4 are designed to utilize the factory bars and replace the stock mounting lugs only. Remove the front brake master cylinder from the right handlebar. It is NOT necessary remove any other controls or grips.
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A) To remove left handlebar:
1. Remove bar end weights.
2. Cut two small cable ties holding wire loom from left control housing (PHOTO 1)­ one under the handlebar anti­ rotation bracket and the other attaching the wire loom to the underside of the top triple clamp. Do the same on the right side.
3. Remove the clutch master cylinder from the left bar.
4. Remove the forward plastic control housing cover (2 screws) Loosen the two screws that sandwich the bar between the forward plate and the rear half of the left control housing(PHOTO 2).
5. Remove the two screws attaching the left handgrip sleeve to the left bar tube­1 on top and 1 on the bottom (PHOTO 3).
6. Remove the anti rotation bracket holding screw located under the top triple clamp (PHOTO 4).
7. Loosen the two screws clamping the left bar to the triple clamp. Only the inner most crew needs to be removed to withdraw the stock bar.
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Mounting the Vacuum Reservoir (10067563)
1. Take out the windshield washer fluid bottle from passenger side by removing the two 10-mm nuts holding it in place.
2. Remove the clutch master cylinder reservoir by popping out the two push clips that attach it to the bracket.
3. The vacuum reservoir is going to be mounted upside-down on the cowl wall with the Amp opening on the top and the Main opening on the bottom.
4. Mount the reservoir using a rivet gun and two 3/16-in rivets, making sure it is not in contact with the hood release or clutch master cylinder reservoir bracket.
5. Replace the clutch master cylinder reservoir by snapping the two push clips back into place.
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Heli Bars are designed to safely increase your riding comfort, however it is imperative that these instructions be followed to ensure correct installation. Failure to follow these instructions could result in improper installation and create a dangerous control situation. If you have any questions about installation call Heli Modified, Inc. at 1­800­859­4642. 1. Remove the damper weights from the ends of the bars. 2. On the right bar, loosen the throttle housing screws enough to spread the housing and disengage the locating pin. It is not necessary to take the throttle housing apart. 3. Remove the front brake master cylinder from the stock bar.
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