9. Rear Turn Signal Installation: Turn signal
mounting requires that you drill a 15/32 inch hole in
either side of the rear fender near where it meets the
side panels to mount the turn signals. You can actually
achieve a clean, durable installation using this mounting
location. See the color photograph, Photo 5 and Figure
2 for the mounting location.
1-1/ 8
1"
Drill 3/ 8" Dia.
Front Edge of fender where it meets side
Figure 2: Left Side View of Fender,
Turn Signal Mounting Location
6
To get the turn signals to be perfectly horizontal,
carefully heat the fender from the inside with a
heat gun. Install a 3/8 inch bolt through the hole
in the fender, using the large fender washers to
sandwich the fender on each side. Using a vise
grip, slowly pull down on the bolt while carefully
heating the plastic from the backside until the bolt
becomes level.
Run the left turn signal wires along with the
taillight wiring forward along the frame rails.
Pass the wires through the gap at the left hand side of the fender just above the fender mounting
bolt. Note that the wires of the right rear turn signal are shorter (5-1/2") than those of the left
turn signal.
Photo 5
Run the right hand turn signal wires similarly along the right frame rail to the area behind the
airbox.
Install
Hydraulic
Switch in place
of Banjo Bolt
Re-Install
Copper Crush
Washer
Run wires up
subframe
Photo 6
10. Brake Light Switch Installation: The latest
KLX kit uses a hydraulic brake switch. This requires
replacing the rear master cylinder banjo bolt with a
specially made switch. Installing the switch requires
bleeding the rear brake. If you do not feel
competent bleeding your rear brake, please refer
this job to a qualified mechanic as failure to do it
correctly will make the brake inoperable.
Remove the banjo bolt from the rear brake master
cylinder, and replace with the hydraulic switch as
shown in Photo 6. Make sure to install the copper
crush washer from the stock bolt under the switch.
Torque the switch assembly to 25 lbf-ft.
