Pre-Assembly
Unpacking
- Cut the straps, then along the dotted line on the bottom of the box; lift the box over the unit and unpack.
- Carefully remove all parts from the carton and inspect for any damage or missing parts. If parts are damaged or missing, contact your dealer immediately.
- Locate the hardware package. The hardware is separated into four steps. Remove the tools first. Remove the hardware for each step as needed to avoid confusion. The numbers in the instructions that are in parenthesis (#) are the item number from the assembly drawing for reference.
Tools and Parts Included
| Tools Included |
| 17mm Wrench (2) |
| Phillips Screwdriver |
| 5mm Allen Wrench |
| 6mm Allen Wrench |
| 8mm Allen Wrench |
| Parts Included | |
| Quantity | Part Name |
| 1 | Main Frame |
| 1 | Console |
| 1 | Console Mast |
| 1 | Center Handlebar |
| 2 | Side Handlebars |
| 1 | Handlebar Bracket |
| 1 | Cup Holder |
| 2 | Console Mast Covers |
| 2 | Console Bracket Covers |
| 2 | Swing Arm Hinge Covers |
| 1 | Hardware Kit |
CE900 Step-by-Step Assembly
1. Console Mast and Center Handlebars
| Hardware Needed for This Step | |||
| PART | TYPE | DESCRIPTION | QUANTITY |
| #46 | Self-Tapping Screw | 3.5 x 12L | 2 |
| #54 | Bolt | M10 x P1.5 x 20L | 12 |
| #57 | Lock Washer | 10 x 16.5 x 2T | 4 |
| #58 | Washer | 4 x 14 x 1.0T | 4 |
| #65 | Washer | 10.2 x 19 x 1.5T | 2 |
a. Gather all hardware needed for this step.
b. Unwind wiring harness and run wires up through CONSOLE MAST (9). Bolt CONSOLE MAST (9) to MAIN FRAME (1) using four BOLTS (#54), four LOCK WASHERS (#57), and four WASHERS (#65). Do not pinch wires.
c. Run wires from CENTER HANDLEBARS (11) through HANDLEBAR BRACKET (10), into CONSOLE MAST (9) and out the top.
d. Install CENTER HANDLEBARS (11) to HANDLEBAR BRACKET (10) using four BOLTS (#52).
e. Install HANDLEBAR BRACKET (10) to CONSOLE MAST (9) using four BOLTS (#54).
f. Attach CUP HOLDER (99) to HANDLEBAR BRACKET (10) using two SELF-TAPPING SCREWS (#46) and two WASHERS (#58).
2. Console Mast Covers
| Hardware Needed for This Step | |||
| PART | TYPE | DESCRIPTION | QUANTITY |
| #47 | Self-Tapping Screw | 5 x 16L | 2 |
| #49 | Screw | M5 x 12L | 6 |
| #78 | U-Nut | M5 | 2 |
a. Gather all hardware needed for this step.
b. Install two U-NUTS (#78) to LEFT CONSOLE MAST COVER (100).
c. Attach CONSOLE MAST COVERS (100, 101) to MAIN FRAME (1) using two SELF-TAPPING SCREWS (#47). Use two SCREWS (#49) to connect covers to each other.
d. Plug in all wires from wiring harness to CONSOLE (111).
e. Install CONSOLE (111) to CONSOLE MAST (9) using four SCREWS (#49). Be careful not to pinch any wires.
3. Swing Handlebars
| Hardware Needed for This Step | |||
| PART | TYPE | DESCRIPTION | QUANTITY |
| #43 | Bolt | M10 x 55L | 2 |
| #44 | Bolt | M10 x 60 | 4 |
| #63 | Washer | 10 x 25 x 1.5T | 10 |
| #68 | Curved Washer | 10 x 23 x 1.5T | 2 |
| #71 | Nut | M10 x 8T | 6 |
a. Gather all hardware needed for this step.
b. Install the LEFT SIDE HANDLEBAR (2) to SWING ARM (12).
i) First, install two longer BOLTS (#44) with a WASHER (#63) on both sides of SWING ARM (12) and a NUT (#71). Do not tighten yet.
ii) Then install one SHORTER BOLT (#43) with a WASHER (#63) through the SWING ARM (12) and CROSS-TRAINING HANDLEBAR (2), using a CURVED WASHER (#68) and a NUT (#71) on the back side.
c. Tighten after all hardware is installed.
d. Repeat process for RIGHT SIDE HANDLEBAR (3).
4. Bracket and Hinge Covers
| Hardware Needed for This Step | |||
| PART | TYPE | DESCRIPTION | QUANTITY |
| #46 | Self-Tapping Screw | 3.5 x 12L | 2 |
| #49 | Screw | M5 x 12L | 6 |
a. Gather all hardware needed for this step.
b. Attach CONSOLE BRACKET COVERS (91, 92) to CONSOLE MAST (9) using two SCREWS (#49). Connect covers together using two SELF-TAPPING SCREWS (#46).
c. Attach left SWING ARM HINGE COVER (93) to SWING ARM (12) using two SCREWS (#49). Repeat for right side.