Kaymar rear bumper installation

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K

KCal

Joined
Dec 15, 2005
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11
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Hi,

I am trying to figure out how to install a Kaymar rear bumper. The instructions contained in the box are pretty difficult to follow. I was staring at the bumper and the instructions last night and did not do anything.

At one point in the instructions, it stated that "Drill out the two centre holes in the main chassis crossmember to 14 mm." I was told before that I wouldn't need to drill any holes for only the bumper installation, but here it said I need to enlarge some holes to 14 mm. I don't think I have any 14mm drill bit. Is it absolutely necessary?

I would appreciate if someone can give me a step by step, or picture by picture, instructions on how to install the bumper. Since the instructions provided by Kaymar is almost useless (e.g., "Make sure you have the correct one in the correct side...."), it will be very helpful for future purchasers.

Thanks in advance.

Vincent

97 LX450, 64K
 
Only holes I had to drill were when I put the tire carrier on and those were for the handle. I don't recall the bumper only requiring any drilling. The two large bolts that go into the rear crossmember should thread right into the threaded holes in the crossmember IIRC.
 
One BIG recommendation that was very unclear in the terrible Kaymar instructions. If you plan on reinstalling the rear mudflaps, PUT THE TOP REARWARD FACING SCREW IN THRU THE MUDFLAP AND IN TO THE FLARE BEFORE PUTTING THE BUMPER ON. If you don't you will have to shorten that screw. There isn't enough room between the flare and the bumper after the bumper is installed to use the full length. Having said that, the only way to then remove the mudflap would be to remove the flare completely (not hard).

The rest is fairly straight forward. You'll have to stare at the wiring for awhile, but it will make sense.

Where are you KCal (Cal for California somewhere)? If close, I can lend a hand.
 
Biff said:
I know that why I posted the 2nd one.
Click to expand...

hehehe - and that one's for the tire carrier only, not the entire bumper. :D
 
Victor, I read the postings that you pointed to before I posted here. It only described the installation of the tire carrier. I am just trying to find the instructions for installing the bumper itself. I know it should be simple, but I am just a little bit frustrated and/or amused by reading the instructions provided.

Thanks,

Vincent
 
They do stink don't they. There are spacers that will need to go between the bottom of the frame and the bumper. I found those HARD to squeeze in. Had a crowbar out to make enough room. Be careful in the side to side alignment when you put the bumper up on the frame so you don't hit either rear quarterpanel. You'll also need to pay attention to the cut out on the PS for the muffler to make sure there's clearance on the muffler so you don't get any rattle. Other than that the six bolts on the underside of the frame go where there are nuts welded into the frame for a standard hitch. You will need to use the square plate with two nuts welded on to slide into each side of the exposed rear frame rails before putting the bumper on. You use those plates for the four bolts that go on the sides of the frame rails.

I'm going from memory here, but I think I've captured the basics of it.

Let me know if it's still not clear and I'll try to help out more. I've been thru what you are doing and was just as disgusted with Kaymar's instructions as you are.

Brent

KCal said:
Victor, I read the postings that you pointed to before I posted here. It only described the installation of the tire carrier. I am just trying to find the instructions for installing the bumper itself. I know it should be simple, but I am just a little bit frustrated and/or amused by reading the instructions provided.

Thanks,

Vincent
Click to expand...
 
Brent, thank you for the offering. I am in Hacienda Heights, which is about 30 miles north of you. Let me go home and try to do it tonight. If I cannot get everything back together, I will ask for your help. Maybe I could drive down to Laguna Niguel. I love your city, but it is too pricey now.

Thanks,

Vincent
 
KCal said:
Brent, thank you for the offering. I am in Hacienda Heights, which is about 30 miles north of you. Let me go home and try to do it tonight. If I cannot get everything back together, I will ask for your help. Maybe I could drive down to Laguna Niguel. I love your city, but it is too pricey now.

Thanks,

Vincent
Click to expand...

No problem. If you can't git r done, I'll be around Saturday afternoon then off to Boy Scout summer camp Sunday. :cool:

Wouldn't take but an hour or so. Let me know. I've also got the correct size drill bits and taps for the handle bolts if you are installing a tire carrier or jerry can carrier, not to mention an installed bumper that's held up quite well to reference. BTW - the bolts that go on the bottom of the frame rail s/b torqued to 75 ft/lbs, same as an OEM trailer hitch. IIRC the Kaymar instructions for torque specs had to be converted to ft/lbs and I'm anal enough to have looked up a conversion table when I did mine.
 
I got the installation done this weekend. My wife and my daughters helped me to put it on. Here are the pics of my truck now. Thanks for everyone help.

One more question, how do you connect the wirings of the lights? I will try to do it next weekend.

Thanks,

Vincent
 
Last edited:
That sure looks better than the factory plastic.

It comes with both spindles like that? Probably good marketing...I bet they sell more tire and can carriers with guys figuring "Heck, I got the spindle already" :)
 
Wow! nice looking LX450. Mine will look like that someday.....
 
One more question, how do you connect the wirings of the lights?
Click to expand...

The lights should come with a harness that clips into some plastic connectors under the floor in back, above the stock spare location. They can only go in one way so pretty hard to mess up, then you figure out what wire does what. The White one is a common ground that grounds to the plate all the bulbs screw into, also to the frame near the connectors. So then turn your lights on and see what wire makes the running light (smallest bulb) come on. then turn your hazards on and see what wire makes the outside lights come on. The other one is the brake, the inside bulbs. bon chance! :cheers:
 
What Nak said. The harness connector is under the truck right above the hitch opening. Only one way to plug it in. Stare at the wires long enough and they will eventually make sense. If you need a trailer wiring harness as well, I just reused my Hoppy converter and spliced the five wires from the Kaymar harness to the Hoppy.

Looks good. Glad it all went on ok.

Did you get the tire carrier as well? When is that going on if so? I do have the drill bits and necessary taps for the bolts that will make that part very easy. Just measure and mark for those four holes at least three times first!!!
 
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