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448 viewsNext, I used a 15/64" (almost 6mm which would work fine) and hand drilled the hole for the grommet (yes, I twisted it with my bare fingers). I wanted to make sure I drilled straight and using a hand-held drill would've caused the hole to be at a slight angle due to the head light housing interfering with the drill chuck.
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448 viewsThe red circled part shows why the lens needs to be angled out when removing it. That hook helps hold the lens in to the housing. The end opposite the hook is where the screw goes.
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448 viewsRepaired pin cut, ground further, and beveled. Fits in the hole nicely! Remember, the planetary ring will move side-to-side so make sure the pin isn't butted against the end of the hole. Allow for the movement.
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Day 4: Monday447 viewsHeaded home with Brian and Shannon's dog, Monk.
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447 viewsMy Sweetie, waiting for chow.
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447 viewsHere's the VR. The center pin is a ground and the easiest way to ground it is to CAREFULLY bend it back onto the backside of the VR body. It will then be pressed against the gauge cluster body that is grounded. The pins are delicate and if you bend them too much they will break!
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447 viewsHere's what they look like. A simple and effective design. Here's where you can get 'em:
http://www.bhpbikeparts.co.uk/content/products/
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447 viewsThe ground lug I used on the left side. Use a ring connector for the grounds. This insures the nut will still make a connection even if the nut gets loosened.
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447 viewsI used a 5/8" socket to support the bearing so I could drive out the push rod.
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447 viewsSize comparison of the incandescent (left) bulb vs. the LED unit (right). Though the LED unit is taller it will still fit inside the signal housing with room to spare.
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446 viewsWhat it looks like when complete. The black paint was removed during the cleaning process.
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446 viewsRight side ground...had to use a 10mm box wrench (spanner).
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Day example.446 viewsDay time demo. Also on YouTube.com at http://www.youtube.com/watch?v=Sr75SJdNsJQ&feature=relmfu
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446 viewsCloser-up. Exploded view. Notice pin is short...it came to us broken.
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445 viewsA good omen...a Porsche Cayman below us. Or else the world's fastest ambulance!
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445 viewsBack at home with the Almquists.
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445 viewsFog harness using a hook on the right side radiator fan surround.
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