Automotive Manual PDF

PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
2. Determine driver and passenger Mounting Brackets.
3. Hang the inner side of the driver front Mounting Bracket into position by partially threading (1) 8mm x 30mm Hex Head Bolt, (1) 8mm Lock Washer, and (1) 8mm Flat Washer into factory threaded hole on the frame (Figure 1). NOTE: There are two threaded holes by the front mounting location on the frame, use the one towards the rear of vehicle.
4. Attach the opposite side of the driver front Mounting Bracket to the threaded holes on the floor panel of the vehicle by partially threading (2) 8mm x 30mm Hex Head Bolts, (2) 8mm Lock Washers, and (2) 8mm Flat Washers (Figure 1).
5. Locate and cut out the openings in the driver and passenger side trimming templates with a pair of scissors (Page 3 & 4)
6. Fit the driver’s side template onto its respective side plastic rock shields. Position them using two each of the 8mm bolts that will later be used to mount the side bar brackets. Transfer the openings in the templates onto the plastic cover using a magic marker.
7. Now remove the rock shield from the undercarriage of the car. The three front screws can be removed with a 10MM socket. The plastic retainer plugs can be removed with a flat blade screwdriver.
8. Using a sharp knife or pair of shears, cut out the shields as marked using the templates (Figure 2).
9. Insert the inner side of driver rear Mounting Bracket through previously cut out hole on the plastic cover. Hang Mounting Bracket by partially threading (1) 8mm x 30mm Hex Head Bolt, (1) 8mm Lock Washer, and (1) 8mm Flat Washer into factory threaded hole on the frame (Figure 3). NOTE: There are two threaded holes on the frame, use the one towards the rear of vehicle.
10. Attach the opposite side on the driver rear Mounting Bracket by partially threading (2) 8mm x 30mm Hex Head Bolts, (2) 8mm Lock Washers, and (2) 8mm Flat Washers into factory threaded holes on the floor panel.
11. Position Driver Side Bar onto Mounting Brackets. Attach Side Bar to Mounting Brackets using the included (4) 8mm x 30mm Hex Head Bolts, (4) 8mm Lock Washers, and (4) 8mm Flat Washers (Figure 1). Do not tighten at this time.
12. Level and adjust Side Bar; then tighten all hardware at this time.
13. Re-install the rest of fastener on the rock shield.
14. Repeat steps 2-13 for passenger Side Bar.
15. Do periodic inspections to the installation to make sure that all hardware is secure and tight.

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STEP 1. Remove the contents from the box and check for any damage. Verify all parts against the parts list.
STEP 2. Read and understand instructions completely before beginning installation.
STEP 3. Determine passenger and driver mount brackets from figure above.
STEP 4. Remove the (16) push type retainers and (2) 6mm bolts from the lower splash shield. Remove plastic splash shield to gain access to mounting locations.
STEP 5. Locate the (4) 14mm holes in the lower radiator support. Attach the mount brackets using the (4) 1/2-13 x 1.00” hex head bolts, (4) 1/2” external-internal tooth lock washer, (4) 1/2” flat washer, (4) 1/2” lock washer, (4) 1/2-14 hex nuts, (2) 5/16-18 x 1.75” hex head bolts, (2) 5/16” lock washer, (2) 5/16” flat washers and (2) 5/16-18 flange lock nuts. Leave loose.
CAUTION: Wheels must be supported to support sub-frame to the unibody to avoid misalignment for re- attachment.
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Time and Ease: Medium difficulty ­ 1­2 hours Tools/Supplies: Wire cutters/strippers, small rotary tool (Dremel), screwdriver, 10 or 15 amp inline fuse, 12v marine outlet with extra wire (Walmart), end connectors that will fit around your battery terminals
Step 1 ­ Open your glove box and locate the dimple or hole in the middle, where the outlet is already on the Forza version. (see photo section) Step 2 ­ If there is a hole already, try fitting the outlet in it. Doesn’t fit or no hole? Try grinding out some of the plastic with a Dremel or rotary tool. BE CAREFUL! You don’t want to grind out too much.
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REMOVING FACTORYAIR DAM
1. To remove factory Air Dam, use a 6” long flat blade screwdriver. The rivets are accessed through the bottom of the bumper behind the factory Air Dam.
2. It will be necessary to remove the factory driving lights by removing the two bolts that hold the plastic light brackets to the bumper. Also remove the nut clips from the bumper.
3. Insert the screwdriver blade into the rivet head slots and twist screwdriver to force rivet inserts downward. Once rivet inserts are 1/4” to 1/2” down, grab with fingers or pliers and pull down, completely removing inserts.
4. After all rivets and lights are removed, use the screwdriver from the front side of Air Dam and pry down on the Air Dam to remove it from the bumper.
5. Next remove the plastic rivet clips from the bottom of the bumper by squeezing the clips and pulling down.
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PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
2. NOTE: It may be necessary to remove/relocate front license plate and license plate bracket. It is not required, but strongly recommended. If local/state law requires a license plate, license plate relocation kit is available.
3. From underside of vehicle, remove the two bolts holding the driver factory tow hook, then remove tow hook from vehicle. NOTE: This Bull Bar is not compatible with factory tow hooks, so you will not be reinstalling factory tow hooks back onto vehicle.
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Installation:
1. Following the vehicle manufacturers instructions, remove the radiator shroud, grill, headlights and turn signals. Then remove the plastic substructure that they are mounted to (Fig. 1).
2. While holding the housing (without lighthead) in the exact mounting location, mark the location of the two mounting holes onto the mounting surface. There is a small notch cut into the inside of the two screw bosses on the housing. Use the notch as a guide, make your mark, then (with the housing removed) measure and make the mounting holes 5-3/8” apart (Figs. 2 & 3). NOTE: Depending on what lighthead you are using with this housing, you will need to drill a wire hole. Refer to the lighthead manual for the size and location.
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Let’s begin by disconnecting the positive terminal of the battery (or removing the battery altogether) and draining the oil. I happened to need an oil/filter change at the same time I was replacing my stator so the timing worked nicely. Some riders will just lean their bikes to the right, against something stable, so that when the left crankcase cover is removed no oil will drain out. Here is the left crankcase cover gasket. I’m holding it upside down, sorry. This is part number 477686-001.
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