INSTALLATION INSTRUCTIONS

Size: px

Start display at page:

Download "INSTALLATION INSTRUCTIONS"

Ella Blair
5 years ago
Views:

1 INSTALLATION INSTRUCTIONS Accessory TRUNK INSTALLATION KIT P/N 08L73-MKC-A10ZA Application GL1800B/BD Honda Dealer: Please give a copy of these instructions to your customer. Publication No. MII Issue Date REVISED February 2018 PARTS LIST No. Description Qty (23) (4) (1) Installation Instructions URL 1 (2) Trunk sub assembly 1 (3) Trunk catch 1 (11) (22) (4) Emergency trunk cable 1 (5) Collar 4 (6) Rubber washer 4 (3) (7) 6 mm bolt 4 (8) (8) 5 mm screw 4 (9) 6 mm screw 6 (10) Clip (short) 4 (21) (24) (11) 5 mm tapping screw (short) (Head: thin) 24 (12) Washer 4 (13) Spring nut 4 (16) (14) Speaker unit 2 (15) Screw grommet 8 (14) (16) 5 mm tapping screw (short) (Head: thick) 8 (17) Stay 1 (18) 8 mm flange bolt (long) 2 (15) (10) (19) 6 mm flange bolt 2 (20) 8 mm flange bolt (short) 2 (9) (2) (25) (21) Backrest 1 (22) Trunk open switch 1 (23) 3 mm screw 1 (24) 5 mm tapping screw (long) 6 (25) Clip (long) 2 (7) (1) (12) (6) (5) (17) (13) (18) (19) (20) 2018 American Honda Motor Co., Inc. - All Rights Reserved. 1 of MKC-A000

2 TRUNK INSTALLATION COLOR KIT Sold separately TOOLS AND SUPPLIES REQUIRED Socket (10 and 12 mm) (4) Ratchet Hex wrench (5 mm) Phillips screwdriver Isopropyl alcohol (1) (5) Shop towel Torque wrench (3) TORQUE CHART Tighten all screws, bolts, and nuts to their specified torque values. Refer to the Service Manual for the torque values of the removed parts. (6) (7) (2) Item N m kgf m Ibf ft 5 mm screw mm tapping screw mm screw mm bolt mm flange bolt (8) 8 mm flange bolt (9) (10) (13) (15) MAXIMUM LOADING CAPACITY The weight of the cargo must not exceed the following maximum loading capacity: (11) Maximum Loading Capacity (12) (14) Trunk 20.0 lb (9.0 kg) No. Description Qty (1) Right trunk side cover 1 (2) Trunk center lower cover 1 (3) Trunk front lower panel 1 (4) Trunk lid 1 (5) Trunk left side cover 1 (6) Trunk right front cover 1 (7) Trunk left front cover 1 (8) Label (MK5-310) 1 (9) Label (MZ3-621) 1 (10) Label (MCA-B31) 1 (11) Label (MCA-G61) 1 (12) Label (MCA-K00) 1 (13) Right rear speaker cover 1 (14) Left rear speaker cover 1 (15) Clip 2 2 of 15

3 INSTALLATION CAUTION To prevent burns, allow the engine, exhaust system, radiator, etc., to cool before installing the accessory. NOTE: Heat the bonding surfaces with a hair dryer if the ambient air temperature is below 70 F (21 C). The adhesive reaches full strength in 72 hours. Wait at least 24 hours before riding your motorcycle. Disconnect the negative (-) cable from the battery before installing this accessory. The memory of the clock will be erased when you disconnect the battery. Reset the clock after reconnecting the battery. Reinstall the removed parts on the motorcycle and make sure that the wires and harnesses are not pinched. 3. Remove the right side cover in the same manner as the left side. 4. Remove the seat as shown. BOLT WASHER SEAT 1. Open the left saddlebag lid as shown. Repeat on the right side. <Left side> 5. Remove the fuse holders as shown. <Left side> FUSE HOLDERS LEFT SADDLEBAG LID 2. Remove the left side cover as shown, and disconnect the negative (-) cable of the battery. LEFT SIDE COVER 3 of 15

4 6. Remove the left pillion step holder cover as shown. Repeat on the right side. 8. Remove the parts as shown. CLIP (Save) SCREW (Save) CENTER REAR TOP COVER BOLT CLIP 9. Remove the center rear top cover as shown. CENTER REAR TOP COVER (Save) LEFT PILLION STEP HOLDER COVER SCREW 7. Remove the right and left rear top lid as shown. LEFT REAR TOP LID (Save) RIGHT REAR TOP LID (Save) 4 of 15

5 10 Remove the rear cross plate as shown. 12. Remove the right and left passenger grip as shown. BOLT (Save) WASHER RIGHT PASSENGER GRIP BOLT REAR CROSS PLATE (Save) LEFT PASSENGER GRIP Remove the cable. COLLAR (Save) CABLE 13. Remove the rear fender as shown. NUT (Save) 11 Remove the clips as shown. SCREW REAR FENDER Disconnect the connector. CLIP 5 of 15

6 14. Remove the saddlebag rear center cowl as shown. SADDLEBAG REAR CENTER COWL 17. Move the left saddlebag and remove the left luggage stay as shown. Repeat on the right side. <Left side> BOLT (Save) SCREW NUT Move. 15. Remove the parts as shown. Repeat on the right side. <Left side> WASHER BOLT (Save) LEFT LUGGAGE STAY (Save) BOLT (Save) LEFT SADDLEBAG BOLT 18. Remove the screws as shown. <Right side> SCREW RIGHT SADDLEBAG SCREW 16. Remove the screw as shown. Repeat on the right side. SCREW 6 of 15

7 19. Move the right saddlebag catch and remove the plug as shown. 21. Route the emergency trunk cable as shown. PLUG (Save) EMERGENCY TRUNK CABLE EMERGENCY TRUNK CABLE RIGHT SADDLEBAG CATCH 20. Install the emergency trunk cable as shown. EMERGENCY TRUNK CABLE GROMMET Insert into the hole. 22. Remove the radio antenna as shown. SCREW RADIO ANTENNA RIGHT SADDLEBAG CATCH 7 of 15

8 23. Install the emergency trunk cable as shown. EMERGENCY TRUNK CABLE 25. Install the stay as shown. Confirm that any wire harness is not caught or too tight. Repeat on the right side. <Left side> 8 mm FLANGE BOLT (long) NUT (Reuse) RIGHT SADDLEBAG CATCH 6 mm FLANGE BOLT 8 mm FLANGE BOLT (short) STAY 26. Install the right and left saddlebag, saddlebag rear center cowl and rear fender in the reverse order of removal. 24. Install the radio antenna and right saddlebag catch in the reverse order of removal. 27. Install the screw grommets as shown. <Right side> SCREW GROMMET TRUNK SUB ASSEMBLY 8 of 15

9 28. Connect the speaker as shown. TERMINAL JOINT 32. Install the right rear speaker cover as shown. RIGHT REAR SPEAKER COVER SPEAKER TRUNK SUB ASSEMBLY TRUNK RIGHT FRONT COVER 29. Install the speaker as shown. 5 mm TAPPING SCREW (short) (Head: thick) 33. Install the clip as shown. TRUNK RIGHT FRONT COVER TRUNK SUB ASSEMBLY CLIP Included in the Trunk Install Color Kit. 30. Install the left side speaker in the same manner as the right side. 31. Install the spring nut as shown. 34. Install the spring nut as shown. SPRING NUT SPRING NUT TRUNK RIGHT FRONT COVER 9 of 15 TRUNK RIGHT SIDE COVER

10 35. Install the trunk right front cover as shown. 5 mm TAPPING SCREW (short) (Head: thin) TRUNK RIGHT FRONT COVER 37. Install the trunk sub assembly as shown. 6 mm BOLT WASHER RUBBER TRUNK SUB ASSEMBLY COLLAR TRUNK RIGHT SIDE COVER 36. Install the left rear speaker cover and trunk left front cover in the same manner as the right side. 10 of 15

11 38. Install the emergency trunk cable to the trunk catch as shown. 40. Connect the trunk catch harness as shown. Secure the emergency trunk cable as shown. EMERGENCY TRUNK CABLE TRUNK CATCH EMERGENCY TRUNK CABLE Secure the emergency trunk cable as shown. TRUNK CATCH 4-PIN WATERPROOF CONNECTOR (Black) TRUNK CATCH HARNESS EMERGENCY TRUNK CABLE 39. Install the trunk catch as shown. TRUNK CATCH TRUNK SUB ASSEMBLY 41. Install the trunk open switch as shown. 3 mm SCREW TRUNK OPEN SWITCH CENTER TRUNK LOWER COVER 5mm SCREW 11 of 15

12 42. Connect the 2P black connector and install the trunk center lower cover as shown. 44. Connect the connector as shown. TRUNK SUB ASSEMBLY HARNESS 2-PIN WATERPROOF CONNECTOR (Black) 2-PIN WATERPROOF CONNECTOR (Black) 5 mm TAPPING SCREW (short) (Head: thin) 2-PIN WATERPROOF CONNECTOR (Black) Route the trunk sub assembly harness as shown. TRUNK CENTER LOWER COVER 43. Remove the dummy connector as shown. <Right side> 2-PIN WATERPROOF DUMMY CONNECTOR (Black) (Save) TRUNK SUB ASSEMBLY HARNESS 45. Remove the dummy connector as shown. <Left side> 2-PIN WATERPROOF CONNECTOR (Black) 12-PIN WATERPROOF DUMMY CONNECTOR (Black) (Save) 12-PIN WATERPROOF CONNECTOR (Black) 12 of 15

13 46. Connect the connector as shown. 48. Install the 5 mm tapping screws as shown. Repeat on the left side. <Right side> 5 mm TAPPING SCREW (short) (Head: thin) 12-PIN WATERPROOF CONNECTOR (Black) TRUNK SUB ASSEMBLY HARNESS 12-PIN WATERPROOF CONNECTOR (Black) Route the trunk sub assembly harness as shown. 49. Install the clips as shown. Repeat on the left side. CLIP (long) CLIP (short) TRUNK SUB ASSEMBLY HARNESS 47. Install the right trunk side cover as shown. Repeat on the left side. <Right side> 50. Install the trunk front lower panel as shown. TRUNK FRONT LOWER PANEL RIGHT TRUNK SIDE COVER 13 of 15

14 51. Install the 5 mm tapping screws as shown. 53. Close the trunk lid. 54. Route and secure the trunk sub harness as shown. TRUNK SUB HARNESS 5 mm TAPPING SCREW (short) (Head: thin) 52. Install the trunk lid as shown. 55. Connect and install the backrest as shown. BACKREST TRUNK LID 6 mm SCREW 56. Install the 5 mm tapping screws as shown. Refer to the motorcycle Owner s Manual and use the emergency trunk cable to open the trunk lid. TRUNK LID 5 mm TAPPING SCREW (long) 14 of 15

15 57. Install the 5 mm tapping screw as shown. Repeat on the right side. <Left side> 59. Install the motorcycle s parts in the reverse order of removal. Confirm that any wire harness is not caught or too tight. 60. Check the speaker, trunk open switch, headlight and the other lights for proper operation. 5 mm TAPPING SCREW (short) (Head: thin) 58. Attach the label as shown. LABEL ISOPROPYL ALCOHOL Thoroughly clean the area where the label will be attached. Select and attach the same label to the saddle bag lid. LABEL SADDLEBAG LID 15 of 15

INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS Accessory LED BRAKE LIGHT P/N 08U76-MKC-A00 Application GL1800/D/DA GL1800B/BD Honda Dealer: Please give a copy of these instructions to your customer. Publication No. MII 16426