The supplied 4mm Allen is a standard allen, however I found it was a little too long to cleanly fit and tighten the screw heads so i took out about half the length and it fit fine.
When the light is installed the lower body portion will interfere if a standard allen wrench is used - hence the modification.
Shown is the general position of the PIAA mount in relation to the Jimmy Mount.
Please note that I have the adhesive mounted under the PIAA mount but I left the side that would touch the Jimmy Mount still covered so it would not adhere.
Flat washer on the top side
Insert the 4mm allen bolt
Larger washer and nut.
Please note the orginal hardware nut is shown - it was here I realized I did not like it and went to the hardware store to replace it with the Nylock style.
OK several things happend here:
1 - once I had the PIAA Light mount installed, I installed the PIAA Light.
[B]NOTE 1[/B] - the PIAA Mount is plastic and Jimmy Mount is metal - you can easily crush the PIAA Mount when tightening - I did it to hand tightness using a 1/4 drive ratchet and socket set up for the nut; while holding the screw in place with the trimmed down 4mm allen wrench.
2 - once the light mount was on the Jimmy Mount, I mounted the Jimmy Mount to the bike using the replacement hardware - again tightening hand tight.
[B]NOTE 2[/B] - this is just temporary as the mirrors still need to be installed. This assembly configuration will allow you to wire the system in place without the mirrors being in the way
3 - repeated the same excercise for the throttle side.
Wiring Harness Prep
Here is the second opportunity to void your warranty!
The wire harness has been supplied with plenty of length - it will be up to the person installing if they want to cut to fit or deal with the excess by dressing it into the bike.
This install is taking into consideration that I have a fuse panel; therefore I will be removing the supplied fuse - green arrow.
[U]If you do not have a fuse panel you have to leave the fuse on.[/U]
Here are the connectors to the lights - if you left them on - these stay, else like I did remove them.
This section of the harness comprises of the on/off switch and the white trigger wire for the PIAA Relay - needs to be connected to 12V.
As stated earlier I plan to integrate the PIAA lights thru my Centech Fuse Panel.
I have substituted the previously installed 10 A fuse with a 20 A fuse (yellow arrow). I also put in the fuse "upside down" for ease of reference when the Centech Panel cover is installed.
This is where the power side of the PIAA lights will be connected.
The Blue Arrow is showing where the White Trigger wire for the PIAA relay will connect.
[COLOR="Red"][B]NOTE - if your aux light system needs to be toggled off when the high beam is on - this location is where the power will be tapped. Post 46 is the start of installing a High Beam Shut Off[/B][/COLOR]
The main power (white) and ground (Black) wires for the lights are shown connected to the Centech.
This is where I mounted my PIAA controller switch - wish I could take credit for its position but i can't as I stole it from a riding buddy.
[B]NOTE[/B] - The PIAA switch has an LED indicator (seen under the PIAA silk-screened text on the switch) and their convention is [COLOR="SeaGreen"]GREEN[/COLOR] for OFF, [COLOR="Red"]RED[/COLOR] for ON. Takes bit to get used to......:lurk
Routing of switch wiring thru the handlebar section - yellow arrow
Shown by the dotted green line is where the main wire harness is run.
As the harness approaches the left (clutch side) mirror the harness needs to split to go to the right (throttle side)
Shown with the Green Arrows is where I placed supporting zip ties to run the throttle side light harness power.
My finger is pointing to the actual harness.