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Upper Air Chaps Installation Instructions |
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Attention: Please read the instructions all the way through BEFORE beginning. It will save you a lot of time and frustration as some of the steps have to be done in exactly the right order. |
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The photos below show how the Upper Air Chaps look when they are properly installed |
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The parts bag contains four stainless steel cushioned clamps and ten #10 stainless steel Nylock nuts (two spares) which are used to clamp the assembled deflector plates to the handlebars just behind the windshield. Make sure the straight section of the handlebar is clean and free of any oil or grease before beginning to install the Upper Air Chaps deflector plates. |
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Remove the clamps from
the parts bag and position them on the handle bars approximately 3
inches apart on the straight section of the handle bars. Make sure the
short tab end is pointing up and the longer tab pointing down. You may
have to shape the clamp slightly to have it fit snuggly on to the
handlebar. |
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Bring the appropriate deflector plate (see the photos at the top of the page) up to the clamps with the screw ends pointing toward the front of the bike. You may have to move the clamps by jiggling them along the handlebar until the holes in the tabs line up with the mounting screws on the deflector plate. Insert the screws into the upper tabs and reach up behind the windshield and thread one of the Nylock nuts on to each upper screw. You have to bring your hand up from below behind the windscreen to be able to reach the end of the screws. |
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Once the upper nuts are threaded several turns on the upper screws, move the lower end of the clamps and line them up with the lower set of screws on the deflector. Thread Nylock nuts on the lower screws several turns. |
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Bring a small socket wrench with a 3/8" socket (a 10 mm socket works well too) up behind the windshield from below to access the nuts on the upper clamp tabs. By moving/lifting the cables the socket wrench can be positioned on the top nuts and they can be tightened. |
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Check the position of the end of the deflector plate and make sure there is 1/8" to 3/16" gap from the grip support clamp on the handle bar. The Urethane pad will be position over the mirror support clamp. If you have to move the deflector in or out on the handlebar do it by gently wiggling the cushion clamps in the direction you want the deflector to move. |
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As you start to tighten the upper nuts position the deflector away from the back of the windshield by about 3/16" to prevent marking the back of the windshield due to vibration. Tighten the upper Nylock nuts until they are firmly seated. Use the screw driver as explained below to hold the screw head from turning. |
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As you tighten the top and then the bottom nuts to pull the deflector plate Urethane friction pads against the handlebar use a screw driver to prevent the head of the screw from rotating. The clamping nut on the fender washers can come loose if you do not do this and the Neoprene fender washers will not grip the deflector plate properly. |
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The photos below show the left and right deflector plates properly mounted on the handlebar with the Urethane friction pads pressing against the handlebar to hold the correct mounting position. |
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| Make sure the Upper Air Chaps clear the gas tank and the gas filler cap when the forks are moved to their full lock position to the right and left. Move the forks SLOWLY to test for interference. If the handlebars have been tilted down significantly there may be interference on either side which will require tilting the handle bars up until the Air Chaps clear. The proper position is shown below. | |
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This completes the installation of the Upper Air Chaps deflector plates. |
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