RUMBUX CRASH BAR INSTALLATION FOR YAMAHA XT660Z TENERE

2009- 2014 models (Three part Kit with Bash plate & Stabilizer brackets. (26/02/2012)

Main frame Stabilizer brackets Bash frame Bash plate

This crash bar is a three part system consisting of a main frame with stabilizer brackets, bash frame and bash

plate. The main frame is mounted first and then the bash frame. Two persons will be required at certain

points, but no special tools are required.

Step 1: Remove the tow-hook underneath the head light by loosening 4 x M6 bolts. (10mm socket &

spanner)

Step 2: Loosen & remove the two M8 bolts and nuts, which attach the head light to the frame, behind the

head light (12mm socket & spanner). Cut the cable tie where the electrical cable is strapped to this

mounting.

Step 3: Remove the Regulator unit on the right front of the engine (see photo in step 10) by loosening 2 x

M6 bolts (10mm socket). Move out of the way or unplug if necessary. This is necessary to reach the engine

bolt in step 5.

Step 4: Remove any existing bash plates.

If a Yamaha tube engine guard is installed remove it completely (Not to be installed again).

Step 5: Remove only the upper engine bolt underneath the water pipe fixing to the engine on the right hand

side of the engine. Don’t remove the engine/frame bracket.

Engine/ Frame bracket

Step 6: You are now ready to position the main frame of the crash bar. Slip the shocks and brake pipes, one

by one, through the opening on the bottom of the main crash bar. This requires an extra hand to maneuver

into position.

Step 7: Locate the bottom mounting bracket first by hooking underneath the bracket of the regulator unit in

order to locate the holes where the engine and frame connects (top bolt in step 5) using the new, longer bolt

M10 x80 Hex head, washer and ny lock nut supplied with kit. Do not tighten yet.

Note the position of crash bar bracket (right bottom) to the mounting bracket of the regulator unit.

Regulator bracket

Note the position of the regulator bracket to the crash bar.

Step 8: Swing the top bracket into position. You might need to remove the bolt in step 8 to gain clearance

over the aluminum base of the shock mounting (don’t unhook the bottom bracket underneath the regulator

bracket). Turn the handle bars a bit to gain clearance. Align the top bracket with the head light mounting

position. Hold it in position. Install the M10 bolt on the bottom bracket, if it was removed. Now install x2

longer M8 x 55mm bolts (in kit) through holes with the nuts and washers through the top bracket. Align

main frame with bike and tighten bolts & nuts at the top and the bottom.

Top Bracket on crash bar main frame.

Step 9: Install Regulator unit.

Step 10: Install the bash frame and bash plate combination. First mount the front of the bash frame and only

then the rear x2 bolts. Locate the bash frame inside the lugs on the main crash bar (see picture below). Install

x2 button head bolts (M10 x25mm) with flat washers and ny lock nuts, but do not tighten yet.

Regulator unit

Step 11: Install new M10 x100mm Hex bolt at the right rear mounting position. (No spacer is required as in

previous installations). Install new M10 x 25 Hex head screw at the left rear position. This might require

some help to push and alight the holes:

Step 12: Install the stabilizer brackets left and right to the Main frame crash bar and the bike frame as

follows:

Note left tube mounts underneath the right tube.

Left tube Right tube

Centre mounting position is behind the radiator. Re route breather pipes if necessary.

Use pipe clamps supplied to mount brackets to the Main crash bar frame

Step 13: Align main frame with top fairing of bike for equal spacing. Tighten all the bolts and nuts.

Step 14: Install the tow hook below the light, which was removed in step 1. Make sure you don’t leave out

the fixing plate bracket for the brake pipes.

Step 15: Use a cable tie to secure the wiring harness, which was cut in step 1, behind the head light.

Note:

If you have used your crash bars in any way (fallen down or dropped the bike), inspect for damage

like hairline cracks as these tends to break off due to vibration at a later stage. Replace damage parts

or have it repaired.

Tighten all bolts and nuts form time to time as vibration on this bike can loosen certain bolts.

Enjoy your Rumbux product!

Manufactured by:

Rumbux 012 754 0999

E-Mail info@rumbux.co.za

Web: www.rumbux.co.za