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Self installation instructions for
Helmets and Speakers


Determine if ear noise reduction muffs will fit in your helmet.
Helmet Speaker Installation | HJC 2012 Model CL Max ll Modular Helmet Installation | HJC 2002 Model SY Max Modular Snowmobile Helmet Installation
Arai XD4 Helmet Installation | HJC 3/4 Open Face FG-JET Snowmobile Helmet Installation | Shoei Neotec Modular Helmet Installation
Scorpion EXO-900 Furtive Transformer Helmet Installation | 2003 Bombardier Advanced Tec BVS Modular Snowmobile Helmet Installation
Motorcycle Half Helmet Installation | SnoForce Full Face Helmet Installation | Ski-Doo Modular 2 Helmet Installation | Tools Needed to Modify All Helmets


3/4 Open Face Helmet
Installation of Ear Noise Reduction Muff Kit in HJC Helmet Model FG-JET


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3/4 (Open Face) Helmet<br> Installation of Ear Noise Reduction Muff Kit in HJC Helmet Model FG-JET
3/4 (Open Face) Helmet
Installation of Ear Noise Reduction Muff Kit in HJC Helmet Model FG-JET
 
Helmet side padding before modifications for ear muffs
Helmet side padding before modifications for ear muffs

Remove side padding and EPS styrofoam side pad
Remove side padding and EPS styrofoam side pad
 
You will need to cut out about 1/2 inch of white styrofoam as shown above for ear muffs to fit over ears properly
You will need to cut out about 1/2" of white styrofoam as shown above for ear muffs to fit over ears properly

Picture above shows ear noise reduction muff in proper location
Picture above shows ear noise reduction muff in proper location
 
Picture above shows EPS styrofoam material cut out of EPS styrofoam side pad where ear muff will be located in helmet
Picture above shows EPS styrofoam material cut out of EPS styrofoam side pad where ear muff will be located in helmet

Place EPS styrofoam side pad over side pad and scratch line in plastic outlining foam pad to be removed along with plastic and fabric
Place EPS styrofoam side pad over side pad and scratch line in plastic outlining foam pad to be removed along with plastic and fabric
 
Fold excess cloth over remaining side pad and glue using Goop product, or rubber cement also works good
Fold excess cloth over remaining side pad and glue using "Goop" product, or rubber cement also works good

Shown is a picture of the small knife I use to cut out styrofoam and plastic on side pad and to cut out side EPS styrofoam.
Shown is a picture of the small knife I use to cut out styrofoam and plastic on side pad and to cut out side EPS styrofoam.
 
Place styrofoam cut out over foam side pad for guide and cut out extra side pad foam. Trim excess cover of side foam pad and glue to vinyl on back of side foam pad with
Place styrofoam cut out over foam side pad for guide and cut out extra side pad foam. Trim excess cover of side foam pad and glue to vinyl on back of side foam pad with "Goop Silicone", not regular silicone. It holds much better.

Side pad modified to fit around ear muff ready to reinstall
Side pad modified to fit around ear muff ready to reinstall
 
Back side of cut out styrofoam needs to be notched for new metal chin strap location that had to be repositioned lower on helmet so it would not be under ear muff
Back side of cut out styrofoam needs to be notched for new metal chin strap location that had to be repositioned lower on helmet so it would not be under ear muff.

Plastic piece on each side ot helmet also needs to be notched for chin strap as shown above.
Plastic piece on each side ot helmet also needs to be notched for chin strap as shown above.
 
EPS side pad surrounding ear muff and held in place with velcro attached to back side of EPS styrofoam and inside of helmet shell
EPS side pad surrounding ear muff and held in place with velcro attached to back side of EPS styrofoam and inside of helmet shell

Pictured above shows new 3/16 inch hole drilled for new location of metal chin. Removing metal chin strap location from under air bladder allows for more room for ear mujff and allows for air bladder to be velcroed to inside of helmet shell.
Pictured above shows new 3/16" hole drilled for new location of metal chin. Removing metal chin strap location from under air bladder allows for more room for ear mujff and allows for air bladder to be velcroed to inside of helmet shell.
 
Metal chin strap rivited into a new location with 3/16 inch pop rivit 1/2 inch long
Metal chin strap rivited into a new location with 3/16" pop rivit 1/2" long

Metal chin strap rivitd into a new location with 3/15
Metal chin strap rivitd into a new location with 3/15" pop rivit 1/2" long
 
Stitching had to be removed from chin strap attached to metal chin strap connector to helmet and was shortened about one inch. Strap was reinstalled on metal chin strap. Holes were melted into strap with soldering gun shown below for installing two 1/8 inch pop rivits by 1/2 inch long through holes. Scotch tape was wrapped around chin strap to hold in place until solder gun melted holes through strap.
Stitching had to be removed from chin strap attached to metal chin strap connector to helmet and was shortened about one inch. Strap was reinstalled on metal chin strap. Holes were melted into strap with soldering gun shown below for installing two 1/8" pop rivits by 1/2" long through holes. Scotch tape was wrapped around chin strap to hold in place until solder gun melted holes through strap.

1/8 inch pop rivits with 1/8 inch washer
1/8" pop rivits with 1/8" washer
 
Solder gun with narrow tip melts hole through chin strap and keeps nylon from unraveling
Solder gun with narrow tip melts hole through chin strap and keeps nylon from unraveling

Picture above shows groove cut in EPS styrofoam in back of helmet for air line between air bladders under ear muffs
Picture above shows groove cut in EPS styrofoam in back of helmet for air line between air bladders under ear muffs
 
Shown is plastic T position connecting air line from each bladder to air pump. Air line comes out of helmet toward back on left side to attach to air pump located on left side of helmet
Shown is plastic T position connecting air line from each bladder to air pump. Air line comes out of helmet toward back on left side to attach to air pump located on left side of helmet

Air line in groove is covered up with sticky back cloth or blue masking tape. It also works well.
Air line in groove is covered up with sticky back cloth or blue masking tape.
It also works well.
 
The modified foam side pad has been glued to styrofoam side pad that has been velcroed to inside of helmet shell
The modified foam side pad has been glued to styrofoam side pad that has been velcroed to inside of helmet shell

Air pump is located further back on left side of helmet to leave room for intercom installation on left side of helmet in front of air pump.
Air pump is located further back on left side of helmet to leave room for intercom installation on left side of helmet in front of air pump.
 
Installation of ear noise reduction muffs is complete.
Installation of ear noise reduction muffs is complete.


 
 

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Helmet speaker installations
Arai XD4 Helmet Installation

Bombardier 2003 Tec BVS Snowmobile Helmet Installation
HJC 3/4 Open Face FG-JET Snowmobile Helmet Installation
HJC 2002 SY Max Modular Snowmobile Helmet Installation
HJC 2012 Model CL Max ll Modular Helmet Installation
Motorcycle half helmet installation
Scorpion EXO-900 Furtive Transformer Helmet Installation
Shoei Neotec Modular Helmet Installation
Ski-Doo Modular 2 Helmet Installation
SnoForce (full face) helmet installation

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