Swapping out std. headlamp surround for Mag Version
 

Anyone know the method for swapping over the headlamp housings on the 749/999
gotta fit my new magnesium one, as yet havent found a cd copy manual, so looking for advice, instructions
cheers:puzzled:

Have a look on this site, Then download to disc. Sorted.

http://www.duc.nu/manuals/

andyb will be be able to give you first had advice i think.

I didn't see a 749 workshop manual on the above site did I miss it ??

Regards

DaveO

Oh go on then.............as you can see the headlamp is in 2 halfs. If you look at whats on your bike.....youll see all the bolt heads around the case. You need to establish which are for holding the two half together, and which hold bits inside like the headlamps, fuse boxes etc etc............

Sorry , my error. It.s an exploded 749. The 999rs04 is interesting.

I have a 999 manual on CD.;)

Really easy Sharpy, just take your time and grease all the bolts when you put them back in. Mine came with a photocopied set of destructions, that gave me some idea of what to find when I undid stuff. With having a good clean of all the nooks and crannies you can get to when it's off it took a couple of hours.
Good Luck

thanx guys, will take a look next week then,
Dougal...an exploded 749, not too sure I wan't one of them !:lol:

would mind a copy of any relevant manuals tho' ? any offers

Did mine today, if you do it in a logical step by step process you can do it without having to disconnect all the wiring loom etc.

Take all body work off, top fairing supports, clocks and plastic cowel from under the headlight casings.

Working from the left there are 4 or 5 bolts that hold the cases together and 2 bolts that hold the casing to the headstock, remove these.

There are 3 bolts that hold each headlight in place, leave these as they are, so the headlights stay in the casing.

On the right casing there is 1 bolt in each headlight, take these out. Cases should now split and you should be able to disconnect the headlights etc. Take the left casing off the bike, remove the headlights, rubber grommits etc out of the left case and transfer these to the new casing.

On the right case there are 2 bolts holding the fuse bax in place, remove these and the various rubber fittings etc. Remove the 2 bolts that hold the right case to the headstock. Bolt the new right case in place and bolt in the fuse box and rubber mounted fittings etc.

Fit the left case in place, connect headlights etc and replace the bolts.

Replace rest of items such as clocks, fairing supports, plastic cowel and top fairing etc etc