INSTALLATION INSTRUCTIONS

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1 INSTALLATION INSTRUCTIONS Accessory Application Publication No. After 13 TRX420 All MII KIT (except 14 TRX420FA/FPA) Issue Date P/N 08T71-HR3-A20 After 13 TRX500 All (except 14 TRX500FA/FPA) September 2014 PARTS LIST SUB-HARNESS Sold separately P/N 08Z01-HR3-A20 (1) (2) (3) The Heated Grips Kit requires installation of the Accessory Sub-Harness (4) (5) (6) (7) (8) (9) (11) (10) (11) (14) (13) (15) (12) No. Description Qty TOOLS AND SUPPLIES REQUIRED Phillips screw driver Torque wrench Socket (10 mm) Socket (12 mm) Ratchet Isopropyl alcohol Shop towel WD-40 Heat gun Electrical tape (1) Right heated grip 1 (2) Left heated grip 1 (3) Shrink tube 1 (4) Mounting strip 1 (5) Pivot mount 1 (6) Handlebar mount 1 (7) Dual zone controller 1 TORQUE CHART Refer to the Service Manual for the torque values of the removed parts. Item N m kgf m Ibf ft 4 mm screw (8) 4 x 14 mm screw 2 (9) 4 x 10 mm screw 1 (10) External lock washers 2 (11) Hex nuts 3 (12) Connector cover 1 (13) Wire tie 1 (14) Wire harness clip 1 (15) Heated grips sub-harness 1 USE AND CARE INFORMATION Check the accessory mounts frequently and retighten if necessary. Read through instructions completely prior to installation of the heated grips kit Honda Motor Co., Ltd. - All Rights Reserved. 1 of 7 08T71-HR3-A20

2 & THUMB WARMER INSTALLATION NOTE: Installation requires WD-40 (Not included) 1. The accessory sub-harness must be installed prior to installation of the heated grips kit. 2. Remove old grips and clean the handlebar surface of any adhesive or residue with isopropyl alcohol. 3. The heated grips may be difficult to install. Apply a considerable amount of force, but do not hammer as this will destroy the grip heater. 4. Three applications of WD-40 are required. Spray the inside of the left grip and the outside of the handlebar with a generous amount of WD Wait two minutes and repeat step Wait two more minutes and repeat step Position the left grip so the wire is facing forward. Align the grip and push it onto the handlebar. IMPORTANT: If the grip cannot be pushed completely on in ten seconds, remove immediately and start over. 8. Position the right grip so the wire is facing forward. Repeat steps Peel the release paper from the thumb warmer and adhere it to the front side of the throttle lever. (Facing the rider) 10. Slide the heat shrink tubing over the thumb warmer and throttle lever. Use a heat gun to shrink the tubing. 11. Route the heated grips wiring harness according to the harness layout (pages 3-6). CONTROLLER INSTALLATION 12. Insert a nut [1] into the slot on the handlebar mount [2]. Insert the mounting strip [3] into the handlebar mount. Fit the mount onto the handlebar on the inboard side of the front brake master cylinder. Install a 15 mm screw [4] through the mount and attach with a nut [1]. Do not tighten completely. 13. Attach the pivot [5] to the handlebar mount using the 8 mm screw [6]. Install a lock washer [7] between the pivot and mount, but do not tighten completely. 14. Place the controller [8] into the slot of the pivot and secure with a 15 mm [4] screw and nut [1]. 15. Rotate the assembly to provide the rider with the best view. 16. Tighten the handlebar mount screw. 17. Remove the controller and set it aside. 18. Tighten the screw attaching the pivot to the mount. 19. Insert a lock washer [7] between the pivot and the controller and insert the screw. Rotate the controller to the appropriate angle and tighten to prevent movement. Left Heated Grip Preparation 1. Wrap a piece of electrical tape around the left heated grip wire at the dimension shown. 180 mm ELECTRICAL TAPE [8] [1] [7] [5] [6] [4] 2. Using the procedures in the Service Manual for the vehicle, remove the right front assembly trim clips. Repeat on the left side. [2] [1] [1] [3] [4] 2 of 7

3 3. Using the procedures in the Service Manual for the vehicle, remove the right front assembly bolts. Repeat on the left side. 5. Remove fuel cap. 6. Remove the front assembly. 4. Disconnect the headlight wiring harness (TRX500: disconnect the accessory socket) from the main wiring harness. 7. Using the procedures in the Service Manual for the vehicle, remove the handlebar cover. 3 of 7

4 8. Remove the left and right grips from the handlebar. Use isopropyl alcohol to remove any remaining adhesive or residue. 10. Install the thumb warmer according to Steps 9 through 10 (page 2). ISOPROPYL ALCOHOL THUMB WARMER NOTE: Read and follow the instructions carefully before starting the installation of the heated grips and thumb warmer. NOTE: Read and follow the instructions carefully before starting the installation of the heated grips controller. 9. Install the heated grips according to Steps 1 through 8 (page 2). 11. Install the heated grips controller according to Steps 12 through 19 (page 2). WD-40 Right Grip: Left Grip: CONTROLLER CONTROLLER HANDLEBAR MOUNT * Be sure to achieve the heated grip angle and wire location as shown in the above image. * Both heated grips should be the same angle. 4 of 7

5 12. Route the right heated grip and thumb warmer harness along the handlebar and under the meter stay. Secure the wire alongside the handlebar with the existing wire tie. Apply electrical tape to heated grip thumb warmer and grip heater as shown. CONTROLLER WIRE HARNESS 13. Route the left heated grip harness along the handlebar and under the meter stay. Secure the harness to the handlebar with the existing wire tie in the position shown. ELECTRICAL TAPE Under the wire tie. EXISTING WIRE TIE Reuse. LEFT HEATED GRIP WIRE RIGHT HEATED GRIP WIRE HARNESS ELECTRICAL TAPE EXISTING WIRE TIE Reuse. THUMB WARMER WIRE HARNESS LEFT HEATED GRIP WIRE TOP VIEW FR LEFT HEATED GRIP WIRE 5 of 7

6 14. Connect the accessory sub-harness to the DLC (4-P red connector) but do not connect the heated grips sub-harness at this time. SUB-HARNESS Do not connect ct at this time. 15. Install the Red and White wire terminals from the left heated grip into the two blank spaces on the 6-pin female connector of the right heated grip. Connect the 6-pin connectors. Connect the Green and White/black wire from the heated grips sub-harness to the Black and Red wires from the 6-pin connector. Slide the connector cover over the sub-harness and cover the 6-pin connector. Attach the wire harness clip into the 7 mm hole located in the meter stay and secure the connector cover. <TRX420 METER STAY LAYOUT> METER STAY WIRE HARNESS CLIP DLC (4-P RED) ACCESSORY SUB- HARNESS WIRE HARNESS CLIP SUB-HARNESS 6-PIN CONNECTOR (MALE & FEMALE) CONNECTOR COVER <TRX500 METER STAY LAYOUT> METER STAY CONNECTOR COVER WIRE HARNESS CLIP 6 of 7 SUB-HARNESS 6-PIN CONNECTOR (MALE & FEMALE)

7 16. Connect the Green and White/black heated grips sub-harness wires to the accessory sub-harness and secure them with the supplied wire tie. 17. Completed wire harness routing for heated grips kit. <TRX420> SUB-HARNESS <TRX500> WIRE TIES (Exising.) WIRE TIE (Supplied.) WIRE TIE (Supplied.) SUB-HARNESS WIRE TIES (Existing.) NOTICE Operate the reverse switch, brake, and throttle at all steering positions to confirm that no wires are pinched or taught. 18. Reinstall the removed parts in reverse order of removal. OPERATING INSTRUCTIONS: After the controller is installed, the heat level of the heated grips and thumb warmer can be adjusted 1. When the ignition is turned on the LED above the word GRIPS will be illuminated. 2. Pressing the ZONE pad will switch between GRIPS and THUMB allowing the heat level of each to be adjusted independently. 3. Press the pad to select the heat level for the heated grips. Each time the pad is pressed another LED will light indicating a higher heat level. Pressing the pad five times will provide the highest heat level. When the pad is pressed again, the heat will shut off and the heat level selection will start over. 4 Press the ZONE pad to select the heat level for the thumb warmer. The LED above the word GRIPS will go out and LED above the word THUMB will illuminate. Press the pad to select the heat level for the thumb warmer. Setting the heat level for the thumb warmer will not affect the heat level set previously for the heated grips. The temperature controller will shut off automatically after two hours if no adjustments are made. To reactivate the temperature controller press the ZONE pad and reset the desired heat levels. Pressing both ZONE and the ~ pads at the same time to change the light level of LED for night or day operation. To turn the controller on or off, press and hold the ZONE button for three seconds. The controller has memory functions. If the power is shut off and then restored, the previous heat settings will be restored. 7 of 7

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