INSTALLATION INSTRUCTIONS

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1 Accessory Application Publication No. INSTALLATION INSTRUCTIONS ATTACHMENT P/N 08T70-MGZ-D80 CB500X/XA MII Issue Date May 2013 PARTS LIST KIT Sold separately (1) (2) (4) (2) (1) (3) BOOT (1 piece.) (3) (4) (5) No. Description Qty (1) Right heated grip 1 (6) (2) Left heated grip 1 (3) Controller 1 (7) (4) Owner s Manual 1 (9) (8) No. Description Qty (1) Installation Instruction URL 1 (2) Heated grip harness 1 (3) Wire tie (narrow) 7 (4) Wire tie (short) 3 (5) Wire tie (long) 3 (6) Boot cover 1 TOOLS AND SUPPLIES REQUIRED Side cutters Ruler Marker Electrical tape ProHonda Handgrip Cement Grease Thread lock Isopropyl alcohol Shop towel TORQUE INFORMATION Refer to the Service Manual for the torque values of the removed parts. (7) Tube A (Length: 110 mm) 2 (8) Tube B (Length: 120 mm) 1 (9) Harness boot Honda Motor Co., Ltd. - All Rights Reserved. 1 of MGZ-D800

2 INSTALLATION CAUTION To prevent burns, allow the engine, exhaust system, radiator, etc., to cool before installing the accessory. NOTE: Disconnect the throttle cables from the right grip as instructed in the motorcycle s Service Manual. For secure adhesion of the left heated grip to the handlebar, use the recommended adhesive agent (Pro Honda Handgrip Cement) and wait until it cures fully before use. Be sure to open and close the throttle to check for smooth operation after installation of the right heated grip. Take care not to damage the painted surfaces of the motorcycle. Reinstall the removed parts on the motorcycle and make sure that wires and harnesses are not pinched. Disconnect the negative (-) cable from the battery before installing this accessory. The memory of the trip meter will be erased and the clock will stop when the battery is disconnected. After reconnecting the battery, refer to the motorcycle Owner s Manual and reset the clock. Trim the excess ends off the wire ties after attaching them to the wire harnesses. Do not allow the cut part of the wire tie to interfere with any harness or brake hose. After heated grip installation, check the lights (e.g. right / left turn signal lights and brake lights) for proper operation. HISS: Some markets have motorcycles equipped with the Honda Integrated Security System (HISS) and can be identified by the HISS mark near the ignition switch. 1. Refer to the Service Manual for the motorcycle, remove the seat. 2. Disconnect the negative (-) cable from the battery as NEGATIVE (-) CABLE BOLT 3. Refer to the Service Manual for the motorcycle, remove the left and right side covers. Repeat on the right side. SEAT BOLTS LEFT SIDE COVER 2 of 16

3 4. Refer to the Service Manual for the motorcycle, remove the left and right shrouds. Repeat on the right side. BOLT 6. Refer to the Service Manual for the motorcycle, remove the meter panel. METER PANEL BOLT CLIP WASHER CONNECTOR Disconnect. BOLT LEFT SHROUD BOLTS BOLT 5. Refer to the Service Manual for the motorcycle, remove the inner cowls. BOLT LEFT INNER COWL CLIP CLIP RIGHT INNER COWL CLIP Remove. 3 of 16

4 7. Remove the handlebar weights from the motorcycle as Repeat on the left side. 9. Remove the right grip as NOTE Refer to the motorcycle s Service Manual and disconnect the throttle cable from the right grip as instructed. Do not try to disconnect the cable with force using pliers, etc. SCREW HANDLEBAR WEIGHT RIGHT GRIP (Save) 8. Remove the right handlebar switch as SCREW THROTTLE CABLES PIN SCREW RIGHT HANDLEBAR SWITCH 10. Mark the right heated grip harness in the position RIGHT 130 mm MARKER RIGHT HEATED 4 of 16

5 11. Apply grease to the parts of the throttle cables and throttle pipe as THROTTLE CABLES 13. Reinstall the handlebar weight as Before applying thread lock, thoroughly clean the screw. SCREW (Reuse) GREASE GREASE HANDLEBAR WEIGHT (Reuse) THREAD LOCK Be sure to apply to the threads of the screw. RIGHT THROTTLE PIPE 12. Install the right heated grip in the reverse order of the motorcycle s grip removal. After installation, refer to the Service Manual and adjust the throttle freeplay. 14. Open and close the throttle grip as Check that the throttle opens and automatically closes smoothly from all steering positions. RIGHT RIGHT 15. Secure the right heated grip harness as Open and close the throttle and confirm that there is no tightness of the heated grip harness. MARK WIRE TIE (narrow) Secure the right heated grip harness at the marked point to the motorcycle s harness. 6 mm 5 of 16 MOTORCYCLE S RIGHT HEATED

6 16. Remove the left grip as 19. Apply Pro Honda Handgrip Cement to the left handlebar as Pro Honda Handgrip Cement LEFT HANDLEBAR ISOPROPYL ALCOHOL LEFT GRIP (Save) 20. Spray isopropyl alcohol over the inside of the left heated grip and outside of the left handlebar. This is done to ease alignment between the heated grip and handlebar. 17. Using isopropyl alcohol, remove all traces of adhesive from the left handlebar. ISOPROPYL ALCOHOL ISOPROPYL ALCOHOL LEFT HANDLEBAR LEFT HANDLEBAR 18. Liberally apply Pro Honda Handgrip Cement to the inside of the left heated grip as NOTE Read the Instructions of steps 18 through 21 carefully before installation and complete the operation quickly before the adhesive cures. Use an assistant to steady the motorcycle while installing the grip. LEFT Pro Honda Handgrip Cement LEFT 6 of 16

7 21. Slide the left heated grip onto the left handlebar as indicated. Wipe up excess adhesive at once. 22. Reinstall the handlebar weight as Before applying thread lock, thoroughly clean the screw. NOTICE Do not tap on the grip end with a hammer and do not twist the grip with force to insert the left heated grip onto the handlebar, as it can damage the heated grip element. Avoid putting pressure on the switch part when inserting the left heated grip. There is a possibility that the switch part will break. Also, install so that there is no gap with the left handlebar switch. SCREW (Reuse) HANDLEBAR WEIGHT (Reuse) If the grip gets stuck halfway during installation, apply isopropyl alcohol between the heated grip and handlebar. Do not try to remove the left heated grip using force or tools as the heated grip element can be damaged. Insert until there is contact with the left handlebar switch, then align with the indicated position. THREAD LOCK Be sure to apply to the threads of the screw. 23. Move the front upper cowl as BOLT LEFT Push in tight against the left handlebar switch. FRONT UPPER COWL Align. HORN BUTTON NUT SHOP TOWEL NUT Loosen. LEFT HANDLEBAR SWITCH LEFT 7 of 16

8 24. Pass the boot over the harness as 27. Fit the boot cover over the boot as BOOT BOOT HEATED BOOT COVER 25. Connect the controller as 28. Secure the boot cover with electrical tape as CONTROLLER ELECTRICAL TAPE 26. Fit the boot over the controller as BOOT COVER BOOT 29. Cut a 2 x 2 mm drain hole at the shaded area of the tube as CONTROLLER TUBE A 2 mm HEATED 2 mm 8 of 16

9 30. Pass the tube over the heated grip harness as 32. Slide the tube as CUT TUBE LEFT HEATED CUT TUBE 31. Connect the heated grip harness as 33. Secure the tube with electrical tape as Secure the tube with its cutout facing down as ELECTRICAL TAPE RUBBER WIRES (Green) WIRES (Blue) Confirm that the rubber is in contact with the base of the heated grip. LEFT HEATED GRIP CUTOUT (DRAIN HOLE) 9 of 16

10 34. Secure the heated grip harness with the wire tie as 36. Secure the heated grip harness with wire tie as MOTORCYCLE S MOTORCYCLE S WIRE TIE (narrow) Secure the heated grip harness to the motorcycle s harness. 35. Route the heated grip harness as BOOT COVER WIRE TIE (short) Secure the heated grip harness to the motorcycle s harness. 37. Place the boot cover as BOOT COVER 10 of 16

11 38. Route the heated grip harness as 40. Connect the heated grip harness as MOTORCYCLE S 3-PIN WATERPROOF CONNECTOR MOTORCYCLE S BOOT HEATED Keep the connected parts in the motorcycle s boot. 39. Remove the dummy connector as 41. Secure the heated grip harness with the wire ties as MOTORCYCLE S WIRE TIE (narrow) Secure the heated grip harness to the motorcycle s harness. DUMMY CONNECTOR (Save) WIRE TIE (short) Secure the heated grip harness to the frame. FRAME WIRE TIE (narrow) Secure the heated grip harness to the frame. 11 of 16

12 42. Pass the tube over each heated grip harness as 44. Slide the tube as TUBE B TUBE B LEFT HEATED 43. Connect the heated grip harness as TUBE B Keep the connected parts in the tube. 45. Route the heated grip harness as LEFT HEATED 12 of 16

13 46. Bundle the right heated grip harness with electrical tape as 48. Connect the right heated grip harness as RIGHT HEATED RIGHT HEATED ELECTRICAL TAPE RIGHT HEATED 49. Slide the tube as 10 mm 130 mm 47. Pass the tube over the heated grip harness as TUBE A Keep the connected parts in the tube. TUBE A 13 of 16

14 50. Secure the tube with electrical tape as Be careful not to damage harnesses. 52. Secure the tube with electrical tape as Be careful not to damage the harnesses. ELECTRICAL TAPE ELECTRICAL TAPE TUBE A TUBE B Cut a 2 x 2 mm drain hole at the shaded tube as area of the Cut a 2 x 2 mm drain hole at the shaded tube as area of the 2 mm 2 mm 2 mm 2 mm 51. Secure the heated grip harness with the wire tie as HEATED MOTORCYCLE S WIRE TIE (Reuse) Secure the heated grip harness together with the motorcycle s harness. 14 of 16

15 53. Secure the heated grip harness with the wire ties as < Models with HISS > 1. Secure each harness with the wire ties as MOTORCYCLE S HOLES COVER WIRE TIE (short) Secure the heated grip harness to the motorcycle s harness. MOTORCYCLE S WIRE TIE (narrow) Secure the tube to the cover. Face the wire tie connected part downward as MOTORCYCLE S WIRE TIE (Reuse) Secure each heated grip harness together with the motorcycle s harness. < Models without HISS > 1. Loosely install the wire tie as S WIRE TIE Secure to the motorcycle s harness. LEFT HEATED WIRE TIE (narrow) Secure the heated grip harness and left heated grip harness to the motorcycle s harness. WIRE TIE (long) Do not tighten yet. IGNITION SWITCH LEFT GRIP HEATER 15 of 16

16 2. Secure each harness with the wire ties as INSTALLED WIRE TIE Tighten to the ignition switch. DEALER TROUBLESHOOTING Stop the engine and turn the ignition switch OFF when you check the parts and circuits other than those of the heated grips. Symptom Heated grip does not operate; Faulty heated grip Faulty heated grip coil Open or short circuit in heater harness Faulty heater switch Check 1. Check whether wires and cables (terminals and connectors) are connected securely. 2. Heated grip inspection Check for resistance between the terminals. Standard: Right : 2.2 ohms +/- 10% Left : 2.2 ohms +/- 10% WIRE TIES (narrow) Secure the tube to the wire tie. Face the wire tie connected part downward as < Common procedures > 54. Check each harness for sufficient freeplay. Move the handlebar right and left and check that the harnesses are not pinched by the neighboring components and that they are not pulled taut. 3. Heater harness inspection: Check for continuity. 4. If no abnormality is found after the above checks 1, 2, and 3, but the heated grip still does not operate properly, replace the heater switch with a new one. It is hard to check the switch with ordinary inspection methods (for continuity, voltage, etc.) because it contains an integrated circuit. 55. Install the motorcycle s parts in the reverse order of removal. Confirm that any harness is not caught or too tight. 56. Move the handlebar right and left and check that this accessory does not interfere with the motorcycle controls. 16 of 16

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