INSTALLATION INSTRUCTIONS - PDF Free Download

INSTALLATION INSTRUCTIONS Accessory FABRIC FRONT DOORS P/N 0SR90-HL4-211A (BLACK) P/N 0SR90-HL4-221A (CAMO) Application SXS1000M3/M3P/M5P/M5D Honda Dealer: Please give a copy of these instructions to your customer. Publication No. MII 15262 Issue Date October 2015 PARTS LIST (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (11) 2015 American Honda Motor Co., Inc - All Rights Reserved. 0SR90-HL4-211A & 0SR90-HL4-221A 1 of 11

No. Description Qty (1) Handle 2 (2) 6 mm washer 2 (3) 6 x 45 mm torx bolt 2 (4) Jacknut 10 (5) 6 x mm bolt 1 (6) 8 mm flange nut 1 (7) 6 x 25 mm flange bolt 16 (8) Threadlocker and alcohol pad 1 ea. (9) Outer door bracket 4 (10) Left and Right door filler 1 ea. (11) Front door (Right and Left) 1 ea. (12) Installation Instruction URL (not shown) 1 TOOLS AND SUPPLIES REQUIRED Gloves Safety goggles Awl Power drill Drill bits (7 mm, 9.5 mm, 11.5 mm) Open-end wrench (10 mm, 13 mm) Hex wrench (4 mm) Torx wrench (T30) Sockets (10 mm, 13 mm, T30 Driver) Torque wrench 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. Item N m kgf m lbf ft 6 mm fasteners 10 1 7.4 USE AND CARE INFORMATION Completely read and understand the instructions before installing this accessory. Do not tow the vehicle on an open trailer with this accessory installed, as the accessory is not designed for use at highway speeds. To clean, sponge with mild soap and cold water, rinse with a hose and allow it to drip-dry. Do not machine wash or dry. Use mild detergent to remove stubborn stains. Do not force the zipper on window. In case of a jam, unzip and remove any obstructions. If problems persist, the zipper must be cleaned. The zipper should be cleaned using a toothbrush with soap and water and rinsed as needed to keep it free of dust and dirt. Once the zipper is cleaned, the teeth should be lubricated with beeswax. NOTICE: If the vehicle is equipped with color panels on the front doors, refer to the Service Manual for the vehicle and remove them. Apply thread locker to the 16 6 x 25 mm bolts and the two 6 x 45 mm bolts following the instructions on the packet. The adhesive loop fastener must be applied at room temperature and given at least 60 minutes to cure before use. INSTALLATION 1. If the vehicle is equpipped with a 2-piece windscreen, trim the left and right door fillers using scissors. Note the placement of the magnet and be sure to avoid cutting into it. MAGNET Jacknut 4.5 0.5 3.3 Cut out if equipped with a 2-piece windscreen. 2 of 11 0SR90-HL4-211A & 0SR90-HL4-221A 2015 American Honda Motor Co., Inc - All Rights Reserved.

B A 2. Remove the trim clips from the front side cover holes closest to the front A-pillar as shown. 3. Install the left and right door fillers between the A-pillar and the front side cover: Fold the lower portion of the door filler to sit underneath the front side cover, so the front portion sits behind the A-pillar as shown. Secure the door filler to the A-pillar with the hook and loop strap. Reinstall the trim clip through the door filler as shown. Be sure the side net buckle (not shown) is free and to the inside of the door filler. TRIM CLIP A-PILLAR HOOK AND LOOP STRAP DOOR FILLER 4. Drill holes into the lower doors: Cut out the drilling templates from pages 7, 9, and 11. Tape the Door, Inside Drill Templates to the inside of the left door as shown. Using an awl, mark the door at the center of each cross-hair. Tape the Door, Outside Drill Templates to the outside of the left door as shown. Using an awl, mark the door at the center of each cross hair. Close the lower door. Align the left fabric door inside of the vehicle cab frame, on top of the lower door, as it will be installed. Verify that all marked hole centers on the interior of the door line up with the centers of the slots on the door brackets. Remove the fabric door. Remove the drill templates from the left door, turn them over and apply them to the right door. Mark and verify the right door following the steps above. Drill 11.5 mm holes at the marked points on the outside of each door. Drill 9.5 mm holes at the upper row marked points of the inside of each door. Drill 7 mm holes at the lower row marked points of the inside of each door. LEFT DOOR SHOWN: <DOOR, INSIDE DRILL TEMPLATE> Drill 9.5 mm holes. FRONT SIDE COVER Align with B Align with A This side up for LHS This side up for LHS door or drill templ ate B HL4 door drill template B HL4 door drill template pate A Drill 7 mm holes. <DOOR, OUTSIDE DRILL TEMPLATE> B B A A This side up for LHS This side up This side up for LHS Drill 11.5 mm holes. 2015 American Honda Motor Co., Inc - All Rights Reserved. 0SR90-HL4-211A & 0SR90-HL4-221A 3 of 11

5. Install the jacknuts: Apply a tapping/cutting or general use oil to the threads of the jacknut. Press the jacknut into the 9.5 mm hole on the inside of the door. Align the 8mm flange nut over the jacknut with the flange down. Thread the 6 x mm bolt through the flange nut and into the jacknut until it is finger tight. Tighten the bolt to the jacknut torque value specified in the Torque Chart. Use a wrench to keep the flange nut from spinning and ensure that the jacknut is seated against the plastic. Remove the 6 x mm bolt. Repeat for each 9.5 mm hole in both doors (four jacknuts total per door). 6. Loosely install a 6 x 25 mm flange bolt into each jacknut, leaving at least 4 mm between the head of the bolt and the jacknut. Install the two spacer plates from the outside of the door and loosely secure them with the 6 x 25 mm flange bolts from the inside. 7. Install the fabric door onto the lower door by pushing the brackets onto the head of each 6 x 25 mm flange bolt, through the keyhole slots in the brackets. Seat the fabric door down on top of the lower door and tighten all the 6 x 25 mm bolts on each door. 8. The rear section of the fabric door frame has a through-hole for a 6 mm bolt. Mark the top edge of the lower door through the center of this hole with a transfer punch or similar. Loosen the 6 x 25 mm flange bolts and remove the fabric door. 9. Drill a 9.5 mm hole into the top edge of the lower door at the marked point. 10. Install a jacknut into the hole using the same process as in Step 5. Reinstall the fabric door and tighten the flange bolts. Install a 6 x 45 torx bolt and 6 mm washer through the hole in the fabric door frame as shown. 6 x 45 mm TORX BOLT WASHER JACKNUT SPACER PLATE JACKNUT 9.5 mm DRILLED HOLE BRACKET FLANGE BOLT 4 of 11 0SR90-HL4-211A & 0SR90-HL4-221A 2015 American Honda Motor Co., Inc - All Rights Reserved.

11. Remove the self adhesive loop fastener from the hook and loop tab at the top of the fabric door. Clean the surface of the upper cab frame, adjacent to the hook and loop tab, with the provided alcohol pad and allow it to dry. Apply the self adhesive loop fastener around the upper cab frame tube, adjacent to the hook and loop tab on the fabric door. 12. Remove the middle two upper bolts from the fabric door brackets. Install the fabric door handle with the removed bolts. Remove the self adhesive Velcro from the flaps and attach it to the brackets, adjacent to with the Velcro on the flaps. Attach the webbing with J-hook onto the lower door handle. UPPER BOLT WEBBING WITH J-HOOK HANDLE SELF-ADHESIVE LOOP FASTENER DOOR BRACKET LOWER DOOR HANDLE 2015 American Honda Motor Co., Inc - All Rights Reserved. 0SR90-HL4-211A & 0SR90-HL4-221A 5 of 11

<TEMPLATE> Door, Inside Drill Template A NOTICE If you print this template from your local computer, make sure the printer settngs do not scale or shrink the page. edge of textured plastic This side up for Left Door 10 20 30 Align with B 10 20 30 2015 American Honda Motor Co., Inc - All Rights Reserved. 0SR90-HL4-211A & 0SR90-HL4-221A 7 of 11

<TEMPLATE> Align with A Door, Inside Drill Template B NOTICE If you print this template from your local computer, make sure the printer settngs do not scale or shrink the page. This side up for Left Door 10 20 30 10 20 30 2015 American Honda Motor Co., Inc - All Rights Reserved. 0SR90-HL4-211A & 0SR90-HL4-221A 9 of 11

<TEMPLATE> NOTICE If you print this template from your local computer, make sure the printer settngs do not scale or shrink the page. A This side up for Left Door B This side up for Left Door Door, Outside Drill Template 10 20 30 Cut out parts and tape together Align A with A and B with B This side up for Left Door A B 10 20 30 2015 American Honda Motor Co., Inc - All Rights Reserved. 0SR90-HL4-211A & 0SR90-HL4-221A 11 of 11