Diamondback 1190 Er - Manual (Page 12)

1190 Series Owner’s Manual 13
1190St Assembly Instructions
Please take the assembly hardware out of the hardware package box. Lay all
the hardware out and take note for its locations. Follow the assembly instruc-
tion step by step to complete the assembly.
Step 1: Frame Assembly
1. Place rear stabilizer bar into the receptor and align the screw holes.
2. Insert and tighten the two M8 x20mm screws, from stabilizer bar hardware
bag, with an Allen wrench.
Step 2: Console Mast Assembly
1. Slide console mast cover onto console mast, making sure it is facing the right
direction.
2. Insert the main wire harness into the bottom opening of the console mast
tube. Push the harness up to the tube until the connector of the hardness
appears in the opening at the top of the tube.
Wiring Harness Installation Hint: Straighten the loops of the wire harness so
that it can slide smoothly into the console mast. Move the console mast cover
all the way to the top. Then hold the bottom of the console mast next to the
console mast receptor and point the top of the console mast downward.
3. Install the console mast by sliding it onto the console mast receptor whiling
pulling the wire harness. This will keep the slack out of the harness so the
wires will not pinched and short out. Insert and tighten the four M8x12mm,
from console mast hardware bag, with an Allen wrench.
4. Place console mast cover in place and align it with screw holes. Insert and
tighten four M5x16mmscrews using a Phillips screwdriver.
Step 3: Handlebar Assembly
1. Insert the hand pulse harness through the opening of the console mast and
out of top of the console mounting plate.
2. Assemble the handlebar onto the mount and insert and tighten the four
M8x12mm screws, from handlebar hardware bag, using an Allen wrench. Be
sure not to pinch the hand pulse harness during this procedure, as this will
damage the electronic console.
Step 4: Console Assembly
1. Connect both plugs, from main wire harness and hand pulse harness, to the
plug receptors on the backside of the console, taking care to install correctly
(see plug alignment marks).
WIRING HARNESS INSTALLATION HINT: Any excess wiring must be carefully
inserted (“stored”) back into the console mast before installing the console
onto the console mounting plate.
2. Fasten the console to the console mounting plate with the four M5x12mm
screws and washers using a Philips screwdriver.
Step 5: Handrail Assembly
1. Place the handrail supports into their receptors on the stabilizer bar. Insert
and finger tighten eight M8x12mm bolts, from handrail assembly hardware
bag, 4 on each side, to secure these supports.
2. Assemble upper handrails into handrail supports. Insert and finger tighten
eight M8x12mm bolts, from handrail assembly hardware bag, 4 on each
Handrail Assembly
1190seriesOM 5/21/08 2:31 PM Page 13