AU XR50 FRONT BAR
FITTING INSTRUCTIONS

 

Procedure -

1. Undo the screws holding the plastic guard to the bottom of the factory bar and remove.

2. Remove the two 10mm bolts and two plastic screws attaching the bar to the radiator support panel.

3. Remove the plastic clips holding the wheel arch guards on to gain access to remove the bar.

4. Remove the two 8mm bolts and the 13mm nut on either side that attaches the bar to the front guard.

 

 

5. Pull the back corners of the bar out and slide forward away from the vehicle, then disconnect the indicators by twisting the orange connectors from the indicator housing.

6. Attach the supplied brackets for the driving lights to the vehicle as shown below. To find the correct position, make sure the bracket is hard up against the corner of the chassis and up until it touches the plastic egg-crate. Then through the tapped hole in the bracket, mark the location for the hole on the vehicle. Drill a 7.5mm hole in the chassis then use the supplied bolt to secure in place.

 

7. To aid wiring of the lights at a later time, attach a length of earth wire to the light as shown.

 

8. Attach driving lights to the brackets, losely at this stage, with the nut, washer, and spring washer supplied.

 

9. To help fitment of new bar, open out the existing mounting holes on either side of the vehicle to 10mm, then apply some paint to the exposed metal edge. (note in this photo the bolt in the middle of the guard bracket, if the bar sits out at all on the sides, loosen this bolt, push bar inwards then re-tighten in position).

 

10. It is now time to prepare the new XR50 bar to attach to the vehicle by fitting the original indicator housings after removing from the original bar. Then sit bar up infront of car close enough to re-attach the indicators.

11. Fit bar onto vehicle.
The first bolts to do up are the two 8mm guard bolts on either side of the vehicle. Pull bar from centre outwards to get a nice fit on guard then tighten up the two bolts (if bar is too low and there is too much of a gap between bar and guard adjust the bracket on the guard, as shown below, up).

 

12. Now do up the two 13mm nuts to the guard, and then the two 10mm bolts on the radiator support panel.

 

13. Adjust the driving lights by hand until they are ligned up with the hole in the bar then tighten the nut on the top of the bracket to hold in place.

14. Refit the plastic underpan then drill the required holes into the wheel arches of the bar and refit the trim plugs.