WELCOME TO YOUR RALLY TOWER INSTALLATION!
If you need to see any portion of the mounting and installation, you can simply rotate and zoom into the 3D model on the side of this text.
The 3D model is an exact replica of the tower you purchased and shows the components as they are mounted.
Further down this page, we have a great list of mounting suggestions and notes.
CLICK ON THE 3D OBJECT TO DRAG IT AND ZOOM IN AND OUT
This model is for you to see how the components fit together.
Installation notes and advice
Overall notes:
This product is aimed at the DIY-minded person. Self-installation will require tools and some practical skills in this area. Installation actions might require drilling, bolting, screwing, cutting, sawing.
Although everything has been done to package this product as an easy assembly unit, the complexity of bikes, model differences, variances, and preferences require an installer to have to make slight adaptations to install correctly.
This is not a complete plug-and-play installation.
Preparation steps: 690/701
| Notes | ||
| 1 | Remove the front bike panels. | Remove plastic front side panels on your bike with the screws |
| 2 | Remove the black plastic panels on the head tube | Remove the black plastic panels that sit around the frame of the bike to see the full headtube. |
| 3 | Remove 690/701 head light. | |
| 4 | Unplug all electrical plugs. | After removing the headlight, unplug all the plugs and group them together to make it easier. |
| 5 | Cut the plastic to remove cables if needed. | |
| 6 | Remove dashboard and dash lights (On newer bikes) | |
| 7 | Remove indicators | Remove and unplug indicator lights and put them to one side. |
| 8 | Unscrew the ignition | Unscrew the ignition (If you have a Husqvarna 701 then just remove the lid of the air box to get easy access.) |
| 9 | Remove the water bottle. | Unscrew the water bottle with a star allen key. |
| 10 | Put tape on the head tube. | When you have clear access to the headtube, Put a layer of tape on the contact points where the head bracket touches the head tube. |
Preparation steps: 500
| Notes | ||
| 1 | Remove the headlight | Remove the front headlight by loosening the rubber fasteners on the shocks. |
| 2 | Unplug all electrical plugs. | After removing the headlight, unplug all the plugs and group them together to make it easier. |
| 3 | Remove dashboard and dash lights (On newer bikes) | |
| 4 | Remove indicators | Remove and unplug indicator lights and put them to one side. |
Installation of headbracket |
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Your tower will be delivered fully assembled with all the bolts loosely fitted. |
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1 |
Remove the three bolts holding the front head bracket to the base tower. |
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2 |
Remove the u-bolt from the front head bracket |
Remove the u-bolt from the front head bracket |
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3 |
Fasten the rear head bracket |
Fasten the rear head bracket in between the ignition and the ignition plate. |
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4 |
Place u-bolt above the water bottle mount |
Place u-bolt above the water bottle mount |
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5 |
Place front head bracket and fasten |
Take the front head bracket and align it to the holes with. Once aligned, place it over the designated bolts with the 2 top bolts having 1 M8 on each side on the inside of the front head bracket and then fasten with a locknut on each bolt on the outside of the bracket. |
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6 |
Adjust your head bracket |
Adjust your head bracket by fastening the bolts on each side until you head bracket is straight |
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7 |
Once your head bracket is secure, fasten your main tower with your 3 bolts again. |
Electronics
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8 |
Remove your rally screen for accessibility |
Remove your rally screen for easy access to the electronics and top plate |
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9 |
Unscrew top plate with allenkie and put to one side. |
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10 |
Thread all electronics into the tower. |
Thread the harshness into the big oval on the right side and the other electronics/cables into the other holes where needed. |
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11 |
Plug all the electronics in. |
Split your headlight plug and the headlight cables. Plug all the rest of the plugs in with the headlight plug separated from the rest. |
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12 |
Screw the indicators onto the tower and plug in. |
Lights
| ## | TIPS for lights | Take the cables of the lights and test to see what colour is bright and what is dim by putting the black cable on the brown/earth and the red on the other 2 colours to determine which is which. |
| 13 | The headlights | The headlights don’t come with plugs. There are 2 ways to tackle the headlights. 1: Source a plug from KTM or Husqvarna and crimp to the headlights and then plugin. 2: Cut the headlight plug from the harness and then solder the cables to the correct cable……..(2 black from the lights go to brown. 1 red goes to the Yellow depending on the bright and dim. Other red goes to blue. |
Finalizing steps
| 14 | Fasten your dashboard | Fasten your dashboard to the dashboard bracket on the top plate(For the 2014 to 2018 KTM690). If you have either the Husqvarna 701 or KTM500, bore 2 holes on the sides of the top plate for the fastening points and then a big one in the center of the top plate for the cables of the dashboard. Then put the dashboard lights through the holes on the top plate |
| 15 | Fasten your top plate. | |
| 16 | Slide your plastic backlight plate behind the lights and cable tie to the aligned rods | |
| 17 | Fasten your rally screen | |
| 18 | Put all the plastic panels back on the bike. | |
| 19 | Take your side plastics and stick the sticker on and place | When your screen is fastened stick the sticker on the panel then fasten the plastic side panels to the screen and tuck them behind the bike side panels to determine where the bottom hole will go.(To make the last hole we suggest using a soldering iron to melt a hole through the plastic.)If the plastic does not fit correctly then cut the plastic for the perfect fit. |
| 20 | After all is done test everything. | |
| 21 | Then enjoy your RALLY RAMPAGE TOWER! |