1. Important Safety Note:
In New Zealand (where this kit is manufactured and complies with NZ law) we
assume all people still alive and still breathing have some degree of common sense.
If you slip on a banana skin in NZ, you can't sue anyone - you're considered an idiot
for not looking where you're walking. These fitting instructions assume the same, so
I won't waste your time with senseless instructions like: "Triumph Crash Bar - Do No
Eat" etc. I will however provide warnings where there are genuine safety concerns,
but if you have any doubt at all, take responsibility for your own safety, read the
manual and/or ASK!
This kit complies with New Zealand standards and conditions only. We have not
sought, and have no intention of seeking certification and design approval for foreign
countries. So if that sort of thing concerns you, don't buy 'it.
We do however, guarantee the quality of our workmanship.
If you spill your coffee on these instructions, you can download a new copy or view
them on our website
Conventions:
LHS and RHS refer to Left Hand Side and Right Hand Side, as the rider sits on the
bike. Front refers the front end of the bike, and rear refers to the back end of the
bike. Well, if you can't work these two out, you shouldn't be left alone without adult
supervision...
Tools needed:

2.  A Metric spanner/socket set, (specifically a 17mm and 19mm combination
spanner and matching sockets)
 A T55 Torx bit and driver for the top engine/crash bar mount bolts, and a T40
to remove the stock lower crankcase bolts.
 A wife or partner/friend to bring more tea/coffee/smokes or yell at when you
skin your knuckles.
Righto Let's get started. Light a cigarette or make yourself a cup of
coffee/tea/chamomile, (or all four), and sit down and read this through before you
start. No beer. This is a Beer Free Zone for the next hour (they should take only an
hour to fit if you're doing it right).
You should be holding one pair of crash bars, 2 x 3mm thick M8 washers, used above
the bottom mounting plate (1 per bolt) and 4 x M8 x 130 socket head bolts.
Remember you are dealing with thread tapped into aluminum - the rule of thumb
with aluminum is that if you can't run a bolt into a thread at least four turns with
your fingers, you are forcing it. Stripped threads can result. Take care, go slowly,
and if in doubt, call on a professional for help.
We strongly suggest you fit the crash bars when your engine is cool, not hot, to
avoid burns from hot components.
Step One:
Fit one side at a time. If you undo the engine mounts on both sides, the engine will
drop. So one side at a time is the best. The right hand side is easier than the left, if
only because you don't have to fiddle with the coolant hose.
So we suggest you fit the right hand side first. The pics below show the fitting of the
RHS. The only difference between the two sides is that on the left you have the
coolant hose to deal with, and a stock spacer to remove on the top rear LHS
mounting.
Firstly, remove the two top engine mounting bolts - the front one supports the
radiator, and you'll need a T55 Torx bit and driver.

3. Then remove the two lower crankcase bolts - you'll need a T40 Torx bit and driver
for this job. (This pic shows the LHS lower crank case bolts)
The crash bar is now ready for fitting. To make the job easier we suggest you pre-
assemble the bolts and washer on the lower mounting.
You'll need your Silicone Sealant now. Smear a thin film of Silicone Sealant on the
upper and lower surface of the lower crash bar mount around the bolt holes.
Offer the crash bars up to the right hand side of engine. Fit the top mount and bolts
first. On the RHS insert the front bolt/washer into the bar before fitting to the bike.
Do up the bottom mount bolts (the ones supplied in the kit) lightly, so the bars are
fitted loosely to the bike.
The bars should still be loose and able to be wiggled on the bottom bolts. Push the
bars up to the two top mounting points and loosely fit the top front mounting.
Move to the rear top mounting point. If you have an alignment problem, loosen the
aluminum top bolt and this will enable you to slide the bolt through easily.

4. Loosen the mounting if you need to and slide the mounting bolt through.
OK, all the mounting bolts are now loosely fitted, right? Now it's time to torque them
up. Progressively tighten the bolts until they are snugged down. Torque the two
lower bolts to 28 Nm and the two top bolts to 80 Nm. Don't mix them up!
Torque the bottom first
Snug the lower bolts down, then torque them to 28 Nm. (push the hose away with
your thumb)
Torque the top bolts to 80 Nm.
OK, that should be it. Before proceeding to the next side, stop for a second and think
the job right through, and read the notes over again. Is everything tight?

5. Last Step:
Thanks for purchasing your crash bars from Thunderbike.
Hope you never need them!

6. NOTES ON FITTING CRASHBARS TO 955 TIGER
Left side 2 x 130mm bolt
Right side will need
2 X thick m8 washer
2 x m8 X 130mm bolt
Use these extra washers only if needed i.e if there is a gap for the
thick washers to fill, if not you do not need them.
Use the longer bolts always as there is a slight risk of damaging
the crankcase thread if the original 116 mm bolts are over
torqued.
Please use this instruction in conjunction with the full fitting
instructions on the Thunderbike website page for these crash bars!
2/46A Muritai street, Tahunanui, Nelson
Phone:+64 (0)3 548 5787
parts@thunderbike.co.nz www.thunderbike.co.nz