Ranger: Light kit installation manual

WARNING!

If You don’t have sufficient mechanical knowledge, experience and proper tools, we strongly recommend, that You have these operations done by Your selling dealer or at Your local motorcycle service center! Making mistake during the disassembly or assembly of the electric system will void the warranty and may cause a hazardous situation, resulting in fire, severe injury or death and damage to property.
For safety reasons it is strongly recommended to leave the battery discharged before handling any component of the motorcycle's electrical system!
Do not let the battery to stay fully discharged, as it may have a negative impact on its capacity. Charge the battery after each ride.

Follow these steps to install the light kit on Your Ranger:

Required tools:

hex wrench #3
hex wrench #4
drill with 5 mm drill bit
wrench #8
cutting plier
duck tape

Make sure, that the magnetic kill switch is in OFF position (magnet NOT attached) and the battery state of charge is very low.
Place the motorcycle on a solid and level surface of a mounting stand, so that both wheels are off the ground.
Using the hex wrench #3 loosen and remove 3 bolts from the left frame cover (above battery) and put the cover aside.
With the same wrench loosen and remove 2 bolts from the inspection lid, located below the controller, and uncover the controller. Uusing the hex wrench #4 loosen the upper controller bolt.
Using the hex wrench #4 loosen and remove 2 bolts from the front number plate holder and remove it.
With the same wrench loosen and remove 1 bolt holding the front fender, cut 2 zip ties and remove the fender from the front fork.
Take the hex wrench #3 and remove the bolt from the back of the rear fender.
Install the taillight and screw in the bolt, removed during previous step, into the lower hole of the taillight holder and into the rear fender reinforcement. Tighten it just enought for it to still be able to move sideways a bit.
Align the taillight in parallel with the side of the rear fender. The light must point backwards, not slantwise.
Use gentle force to make a hole into the rear fender using a drill with 5 mm drill bit (the fender is plastic). Be highly aware of the rear tire and avoid any contact between the drill and the rear tire. To be absolutely sure You won’t make a contact with the rear tire, You can cover it with a piece of sheet metal, or You can remove the rear wheel. The instructions on how to remove and reinstall the rear wheel can be found in the Ranger manual. The manual is available for view and download at www.kuberg.com/owners-manual.
Gently pull the rear fender up with one hand by approx. 2,5cm (1”) and insert the supplied bolt into its upper hole. Use the supplied washer and the locking nut from the bottom side of the rear fender.
Secure the taillight to the fender with the hex wrench #3 and the wrench #8 (5 - 6 Nm on both bolts).
Run the cable along the rear fender reinforcement, below the rear brake calliper and along the upper and front tube on the left side of the rear swing arm. Use supplied zip ties according to the picture. You can remove the original zip ties holding the brake hose to the swing arm, but avoid the taillight cable and brake hose to make any contact with the rear brake disc or rear tire!
Run the cable under the motor and above the battery, along with the main motor cables. Use supplied zip ties to fasten the taillight cable to the frame.
Thread the cable connector through the rubbered eye on the left upper side of the frame. You can use pliers (not supplied), but be very careful not to damage the connector or the pins inside.
Gently push the cable under the controller, according to the picture.
Take the supplied short cable with the fuse and thread its red and black connectors from the inside of the frame up through the same rubbered eye as in step #15. Again, push the lower part of the cable with the yellow connector under the controller.
Connect the yellow connector to the corresponding connector on the controller, temporarily covered by the shrink tube.
Make sure the main light switch on the voltage converter holder is in OFF position.
Connect the upper connectors from the short cable to the switch on the voltage converter - red beside red and black beside black.
Use the hex wrench #4 and 2 bolts, removed during step #5, and tighten the voltage converter to the fork upper plate.
Take the headlight from the big plastic bag and assemble it according to the pictures.
Use the supplied 3M tape to stick the rubber into the lower holder for the high/low beam switch.
Loosen the kill switch bolt and move the kill switch on the handlebar to the right to create a space for the high/low beam switch. Retighten the bolt when finished.
Using cross screwdriver (not supplied) to install the high/low beam switch on the left side of the handlebar, according to the picture.
Install the headlight onto the front fork just by using the 2 lower rubber belts. For better access during the rest of the light kit installation leave the upper rubber belts detached.
Connect the white connector from the high/low beam switch on the handlebar to the corresponding white connector on the voltage converter.
Use the supplied small zip tie and secure the fuse (black box) onto the lower side of the voltage converter holder.
Secure the 2 upper rubber belts of the headlight onto the front fork.
Start the motorcycle by putting the kill switch in ON position, put the main light switch in ON position and check the front and the rear light function and also the function of the high/low beam switch. If both lights don’t light up, double check the whole installation process step by step. If everything works fine, put the kill switch in OFF position (magnet detached).
Install the front fender back to its place, tighten its bolt using the hex wrench #4 and secure the front fender position with supplied zip ties.
With the same wrench tighten the upper controller bolt.
Reinstall the inspection lid and 2 bolts holding the inspection lid on the frame and using the hex wrench #3 tighten them (5 - 6 Nm).
Reinstall the left frame cover using 3 bolts, removed in step #2, and using the hex wrench #3 tighten them (5 - 6 Nm).
Check all bolts for tightness and cut unnecessary ends of all used zip ties. Be extra careful not to cut any cable or brake hose!
Find level surface with at least 12m (39ft) of free space and a blank wall of one color.
Using a duck tape mark the height of 85 cm (2ft 9”) above ground.
Set the front and rear suspension accordingly to the rider's weight.
Dim the room lighting (or wait till nightfall), let the rider sit on the motorcycle and point the front light vertically onto this wall.
Reverse the motorcycle perpendicular from the wall to the point, where the center of the front wheel will be distant 10m (32ft 9”) from the wall.
Using the adjusting bolt under the front light (visible from the front) set the upper edge of the light cone on the wall to touch the duck tape.

If Your motorcycle is under warranty, please register it on our website, if You have not already done so:
https://www.kuberg.com/en/bike-registration

If the problem persists, please contact Your dealer or KUBERG customer service (support@kuberg.com). For the fastest possible resolution please send:

VIN of Your motorcycle (it is stamped on the right side of the steering column).
Detailed information on actions taken so far, a few photos and preferably a video.

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Ranger: Light kit installation manual

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