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How-to: Install MC Engine Guard / Crash Bar
Just installed one myself as my first project on the bike.
I took some pics during the process to make it easy to identify where the bolts go, etc. I am a newbie, so it took me a while to figure things out, etc. It took a little more than an hour for me to install it. May take 15-30 mins for people more experienced with tools/bikes. Need to go to a Chicago Fire game now, but will update the post later this weekend with pics, scanned installation instructions that came with engine guard, etc. UPDATE - Instructions and installation pics attached below. Instructions that come with the engine guard are pretty intuitive, hopefully pics below will help as well. [attachment=1:2jzet11i]MC_Engine_Guard_Instructions.pdf[/attachment:2jzet11i] Before horn is removed (i.e. stock) http://s1.postimage.org/osmj1vr8/IMG_1312.jpg After horn is removed http://s1.postimage.org/osrhnx8k/IMG_1313.jpg At this point, you can use the same bolt that was holding the horn in place, and put the top piece of the engine guard in place, i.e. same place that the horn was at before. Last step of the installation, you'll install the horn on the new location on the engine guard, pretty close to where it was before. Using 2 size 12 wrenches to take out the stock lower motor mount bolt. http://s1.postimage.org/ost579qc/IMG_1315.jpg Another angle that shows the location of lower motor mount bolt. Notice that we dont need to do anything with those similar bolts on the upper side of the engine http://s1.postimage.org/oswg9ypw/IMG_1317.jpg\ This is how it looks when the lower bolt is taken out. http://s1.postimage.org/ot1ew078/IMG_1319.jpg AND this is the "Oh sh*t" moment. After placing the lower part of the engine guard and putting in the longer bolt that comes with the engine guard, aligning the spacer, etc. it gets a little crunched in there. Regardless, you can use a size 12 and size 13 wrench to tighten everything up. After 15 minutes of dealing with that, and assuming I was done, realized that I forgot the little washer. This is the first time I thought I was done... http://s1.postimage.org/ottj0wlg/IMG_1320.jpg Took the bolt out and put the washer in before starting again. Here is that pic. However, with the washer in, bolt ended up being just the right size on the other size, and I had trouble putting the nut in by myself (this is one point that I could've used another hand). Trying to squeeze, put in the nut at the same time, I missed the thread, and basically messed up a small portion of the bolt and the nut. http://s1.postimage.org/oua2edj8/IMG_1321.jpg No biggie though, quick trip to the hardware store, and getting slightly longer bolt, nut and washer (for 95 cents) got me going again. I don't think this would be necessary for somebody who can put the bolt and nut together properly ... Next picture is after everything is said and done about the lower level part of the installation. Putting the horn back will be the next step. http://s1.postimage.org/ouvkdvyc/IMG_1322.jpg I thought putting the horn and the reflectors back to the last remaining spot on the engine guard was a little tricky, once again due to space reasons. Had a little trouble holding reflector piece, honk and short stock bolt (that came out earlier) on my right hand and nut and the washer on my left hand to put them together. One thing that helped me after a few trials and errors, was to hold the nut and washer on left hand, reflector piece on right hand, put reflector in piece, and transfer it to the left hand, than pick up bolt and horn with right hand and put everything together. Once again, if you have a little more experience with nuts and bolts this should be pretty ez for you. It took a while for me to figure it out. Here is how it looks after it's said and done. http://s1.postimage.org/ow96iaro/IMG_1330.jpg A few more close ups: http://s1.postimage.org/owchkzr8/IMG_1328.jpg http://s1.postimage.org/owe54c90/IMG_1331.jpg http://s1.postimage.org/owfsnoqs/IMG_1332.jpg And the final product :2tup: [attachment=0:2jzet11i]IMG_1327.jpg[/attachment:2jzet11i] Hopefully this helps others who may be thinking about adding an engine guard to their GZ250s. |
Re: How-to: Install MC Engine Guard / Crash Bar
Sounds good. Can't wait to see the photos, etc.
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Re: How-to: Install MC Engine Guard / Crash Bar
Oh my that looks just right. MC did just the right size and shape for the GZ. Not just a mere decoration like the Suzuki bars. Now there is someplace for highway pegs when you want to stretch out. What's next ?? Heated grips, LED driving lights to help be seen by others ??
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Re: How-to: Install MC Engine Guard / Crash Bar
Thanks WW. Next up is to properly setup the generic memphis shades short windshield I bought used.
The guy I bought it from messed up one of the clamps when he was putting them on my bike, so ordered a new clamp on ebay. When that arrives, want to install it properly for partial wind protection. (it is kinda short, so I did not really like it that much, but the price was right to try out my first windshield. I know what to look for when I buy another windshield now) I may take it easy a little bit after that for a while. But saddlebags & sissy bars would be next I believe... I'll check the forum to see what kind of options there are out there... And what to watch out for during the installation. |
Re: How-to: Install MC Engine Guard / Crash Bar
Nice job ArdaBey! Thanks for sharing. :2tup:
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Re: How-to: Install MC Engine Guard / Crash Bar
Nice job on the write up and installation. Looks good on the bike!
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Re: How-to: Install MC Engine Guard / Crash Bar
Found out about one thing that I missed during the installation. Good thing that it was not a bad mistake.
If you check out the pic right before I said "a few more closeups", you'll notice that the reflectors are awfully close to the exhaust pipes. Turns out that this is not a good thing :) After my trip today, I noticed some smell. Bottom portion of the reflectors were burnt out. Double checked the bolt, and it was in there tight. First thought about taking the reflectors out, then decided to bend the metal part that holds the reflectors upwards a little so that there is enough space in between the exhaust and reflectors. I think this will work out in the long term. Lesson learned: Make sure nothing touches or is very close to the exhaust pipes... They will get burned otherwise. |
Re: How-to: Install MC Engine Guard / Crash Bar
For your next project add a headlight modulator (fits into the headlight bucket) and brakelight modulator. Easy to do and well worth the safety features.
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Re: How-to: Install MC Engine Guard / Crash Bar
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I'll post my install for comparison. |
Re: How-to: Install MC Engine Guard / Crash Bar
When I put mine on I never had to move any reflectors either.
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Re: How-to: Install MC Engine Guard / Crash Bar
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Re: How-to: Install MC Engine Guard / Crash Bar
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Re: How-to: Install MC Engine Guard / Crash Bar
Assembled:[attachment=2:1mxp2q93]DSCI0011.JPG[/attachment:1mxp2q93][attachment=1:1mxp2q93]DSCI0012.JPG[/attachment:1mxp2q93][attachment=0:1mxp2q93]DSCI0013.JPG[/attachment:1mxp2q93]
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Re: How-to: Install MC Engine Guard / Crash Bar
Nice. Thanks for the update and pics.
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ACK! My foot brake hits the MC Engine Guard!
ACK! My foot brake hits the MC Engine Guard!
[attachment=2:1wzua6a5]DSCI0015.JPG[/attachment:1wzua6a5] I had adjusted the screw here to be further up the cable. [attachment=1:1wzua6a5]DSCI0018.JPG[/attachment:1wzua6a5] Now it doesn't hit. [attachment=0:1wzua6a5]DSCI0019.JPG[/attachment:1wzua6a5] For each one full revolution of the adjustment screw, I tested the brake to see if it would hit. I stopped as soon as it didn't by hand pressure and I could see a little gap. I wish to confirm this is the correct thing to do! |
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Just me trying to show off my toy with everyone else. :2tup: |
Re: How-to: Install MC Engine Guard / Crash Bar
IIRC, there's an adjustment screw on the brake pedal itself which you can use to alter the position of the brake pedal. Don't stop at hand pressure though, you're foot is going to put a lot more pressure on there when you want braking power.
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Re: How-to: Install MC Engine Guard / Crash Bar
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If all else fail just bend the pedal to the side a bit if it will provide clearance. Above all the brake pedal has to be there under your foot when needed, not somewhere in the vacinity and you have to search for it. |
Re: How-to: Install MC Engine Guard / Crash Bar
IMHO it seems like a design fault. Strange that the manufacturers haven't picked up on it. :??:
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Re: How-to: Install MC Engine Guard / Crash Bar
That's very common with the MC guard. You have to adjust the pedal first with the screw under there to change it's height/.angle, and it has to clear the guard when it's fully depressed by standing on it (*not with just hand pressure) like you would do using the brake, otherwise it will hit against the guard and prevent you from applying enough pressure to activate the rear brake. Then you have to adjust it from the rear if you need to, and like WW said, screw (literally) with the brake light adjustment so that the light goes on as soon as you move the pedal downward. It'll only take 5-10 min at most to get this all right, and the hardest part is to see the light go on when you depress the brake pedal.
It always pays to read the manual to see how things are done, and if you don't have one, download it from here. |
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