Before installing my Yamaha passing lamps, I did some research on this site. Many talked about how hard the alignment was…and they were correct!

During my install, however, I came up with a little gadget that may help those having these lamps.

If you take a look at the shoulder washers, you will note that their hole is rather oversized compared to the one on the light bar and the diameter of the “special bolt”. I’m sure Yamaha did this to allow movement and therefore adjustment.

The problem is that when tightening, the washers tend to “squirt” to one side or the other making alignment a real pain.

When I noticed this during my frustrating moments of trying to align, I wished I had some “insert” or “bushing” to take up some of that space. Then it came to me! TUBING.

I looked around my garage and found some leftover tubing. I cut a piece the thickness of the shoulder washer and slid it over the special bolt.

VOILA! This took up most of the sloppy-slack but still allowed me to adjust slightly if needed. When you assemble, the new “tubing bushing” helps to hold all the parts more centered for tightening.

I made up a Fred-and-Barney drawing so others could visually see what I’m talking about.

The key is to find tubing that has an ID to fit snug on the “special bolt” and an OD that will still fit inside the shoulder washer. The tubing I used had a 3/8” ID and a 9/16” OD.

I hope this helps someone from spending those FRUSTRATING hours trying to align these lamps.

<br><br>Post edited by: Katana, at: 2007/06/09 12:02