Accessory Application Publication No. INSTALLATION INSTRUCTIONS S ATTACHMENT KIT P/N 08T70-MJW-D90 After 15 CB500X/XA Honda Dealer: Please give a copy of these instructions to your customer. MII 15802 Issue Date March 2016 PARTS LIST (1) KIT Sold separately (2) (4) (2) (1) (3) (10) (4) (6) (3) No. Description Qty (1) Right heated grip 1 (7) (5) (2) Left heated grip 1 (3) Controller 1 (4) Owner s Manual 1 (8) (9) (11) (12) No. Description Qty (1) Installation Instructions URL 1 TOOLS AND SUPPLIES REQUIRED Side cutters Ruler Marker Electrical tape Pro Honda Handgrip Cement Grease Isopropyl alcohol Shop towel TORQUE CHART Refer to the Service Manual for the torque values of the removed parts. (2) Heated grip harness 1 (3) Wire tie (narrow) 7 (4) Wire tie (wide/middle) (Not used.) 3 (5) Wire tie (wide/long) 3 (6) Boot cover 1 (7) Tube (narrow) 2 (8) Tube (wide) 1 (9) Harness boot 1 (10) Wire tie (wide/short) 2 (11) Clamp 1 (12) Clip band 1 2016 American Honda Motor Co., Inc. - All Rights Reserved. 1 of 15 87951-MJW-J800
INSTALLATION CAUTION To prevent burns, allow the engine, exhaust system, radiator, etc., to cool before installing the accessory. NOTE: Disconnect the throttle cable from the right grip as instructed in the motorcycle s Service Manual. For secure adhesion of the heated grips use the recommended adhesive agent (Pro Honda Handgrip Cement) or equivalent. Be sure to open and close the throttle to check for smooth operation in any steering position after installation of the right heated grip. Disconnect the negative (-) cable from the battery before installing this accessory. 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. 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 another harness or brake hose. After heated grip installation, check the lights (e.g. right / left turn signal lights and brake lights) for proper operation. 2. Remove the left side cover as <Left side> LEFT SIDE COVER 3. Remove the left shroud as CLIP WASHER 1. Remove the seat and disconnect the negative (-) cable of the battery. SEAT LEFT SHROUD 2 of 15
4. Remove the left inner cowl as LEFT INNER COWL CLIP 7. Remove the handlebar weight as Repeat on the left side. <Right side> SCREW HANDLEBAR WEIGHT 8. Remove the right handlebar switch as CLIP Remove from the left inner cowl. SCREW 5. Remove the right side cover, right shroud and right inner cowl in the same manner as the left side. 6. Remove the meter panel as METER PANEL PIN CONNECTOR Disconnect. SCREW RIGHT HANDLEBAR SWITCH 3 of 15
9. Remove the right grip as NOTE Disconnect the throttle cable from the right grip as instructed in the motorcycle s Service Manual. Do not try to disconnect the cable with force using pliers, etc. 11. Install the clip band on the marked position as RIGHT MARK (90 mm) RIGHT HEATED GRIP RIGHT GRIP (Save) CLIP BAND 12. Apply grease to the parts of the throttle cables and throttle pipe as THROTTLE CABLE THROTTLE CABLE GREASE GREASE 10. Mark the right heated grip harness in the position RIGHT RIGHT THROTTLE PIPE 90 mm MARKER RIGHT HEATED GRIP 4 of 15
13. 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. 16. Install the clamp as RIGHT (Reuse) CLAMP 14. Open and close the throttle grip as Check for smooth opening of the throttle and that it automatically snaps closed from any opening, in all steering positions. 17. Secure the right heated grip harness as Open and close the throttle and confirm that there is no tightness of the heated grip harness. <Right side> RIGHT HEATED GRIP RIGHT HEATED GRIP CLAMP CLIP BAND 18. Route the right heated grip harness as 15. Remove the bolt as RIGHT HEATED GRIP 5 of 15
19. Remove the left grip as <Left side> 22. Apply Pro Honda Handgrip Cement to the left handlebar as PRO HONDA HANDGRIP CEMENT LEFT HANDLEBAR ISOPROPYL ALCOHOL LEFT GRIP (Save) 23. Spray isopropyl alcohol over the entire inside of the left heated grip and outside of the left handlebar. This is done to ease installment of the heated grip onto the handlebar. 20. Using a isopropyl alcohol, remove all traces of adhesive from the left handlebar. ISOPROPYL ALCOHOL ISOPROPYL ALCOHOL LEFT HANDLEBAR LEFT HANDLEBAR 21. Liberally apply Pro Honda Handgrip Cement to the inside of the left heated grip as NOTE Read the Instructions of steps 21 through 24 carefully before installation and complete the operation quickly before the adhesive cures. Use an assistant to steady the motorcycle while installing the grip. LEFT LEFT PRO HONDA HANDGRIP CEMENT 6 of 15
24. Slide the left heated grip onto the left handlebar as indicated. Wipe up any excess adhesive at once. 25. Remove the parts as <Front side> NOTICE Do not tap on the grip end with a hammer and do not twist the grip to install the heated grip onto the handlebar, as it can damage the 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 switch holder. NUT If the grip gets stuck halfway during installation, apply isopropyl alcohol to the gap between the heated grip. Do not try to remove the heated grip using force or a screwdriver, etc. Damage to the heated grip wire can result. 26. Move the front upper cowl as Protect with a shop towel or similar, and take care not to damage the front upper cowl. FRONT UPPER COWL Insert until there is contact with the left handlebar switch, then align with the indicated position. LEFT Push in tight against the left handlebar switch. SHOP TOWEL NUT Loosen. Align. HORN BUTTON 27. Pass the harness boot through the heated grip harness as BOOT LEFT HANDLEBAR SWITCH LEFT 7 of 15
28. Connect the controller as CONTROLLER 32. Cut the area of the tube as TUBE (narrow) 2 mm 2 mm 29. Fit the harness boot over the controller as BOOT 33. Pass the tube and cut tube over the heated grip harness as CONTROLLER CUT TUBE 30. Fit the boot cover over the harness boot as BOOT COVER TUBE (wide) BOOT 34. Connect the heated grip harness as <Left side> 31. Secure the boot cover with electrical tape as WIRE (Green) ELECTRICAL TAPE BOOT COVER WIRE (Blue) LEFT HEATED GRIP 8 of 15
35. Slide the tube as 38. Slide the tube as TUBE (wide) CUT TUBE LEFT HEATED GRIP 36. Secure the tube with electrical tape as Secure the tube with its cutout facing down as Confirm that the rubber end is in contact with the base of the heated grip. TUBE (wide) Keep the connected parts in the tube. RUBBER END CUTOUT ELECTRICAL TAPE 39. Pass the grip heater harness through the tube as <Right side> ELECTRICAL TAPE 37. Connect the heated grip harness as TUBE (narrow) LEFT HEATED GRIP 9 of 15
40. Connect the right heated grip harness as 43. Cut the area of the tube as Be careful not to damage harnesses. RIGHT HEATED GRIP TUBE (narrow) Cut the area of the tube as 41. Slide the tube as 2 mm 2 mm TUBE (narrow) Keep the connected parts in the tube. 44. Secure the tube with electrical tape as 42. Secure the tube with electrical tape as ELECTRICAL TAPE TUBE (wide) ELECTRICAL TAPE ELECTRICAL TAPE ELECTRICAL TAPE TUBE (narrow) 10 of 15
45. Cut the area of the tube as Be careful not to damage harnesses. 47. Secure the tube with the wire ties as INSTALLED WIRE TIE Tighten to the ignition switch. TUBE (wide) WIRE TIE (narrow) Secure the tube to the wire tie. Face the wire tie connected part downward as Cut the area of the tube as 2 mm 2 mm 46. Loosely install the wire tie as WIRE TIE (wide/long) Do not tighten yet. IGNITION SWITCH 11 of 15
48. Secure the heated grip harness and left heated grip harness with the wire tie as <Left side> MOTORCYCLE S 50. Secure the right heated grip harness with the wire ties as <Right side> Face the wire tie connected part forward as LEFT TUBE MOTORCYCLE S MOTORCYCLE S WIRE TIE (Reuse) Secure the heated grip harness, left heated grip harness and motorcycle s harness to the handlebar pipe. 49. Secure the tube with the wire tie as MOTORCYCLE S RIGHT HEATED GRIP WIRE TIE (narrow) Secure the right heated grip harness to the motorcycle s harness. MOTORCYCLE S WIRE TIE (Reuse) Secure the right heated grip harness and motorcycle s harness to the handlebar pipe. TUBE WIRE TIE (narrow) Secure the tube to the motorcycle s harness. Face the wire tie connected part forward as 12 of 15
51. Secure the heated grip harness with the wire ties as 53. Route the heated grip harness as WIRE TIE (narrow) Secure the heated grip harness to the clamp. CLAMP 54. Connect two wire ties as WIRE TIE (wide/long) 55. Secure the heated grip harness and boot cover with the wire ties as RELAY BOX BOOT COVER 52. Secure the heated grip harness with the wire tie as S WIRE TIE Secure the heated grip harness to the motorcycle s harness. CONNECTED WIRE TIES Secure the heated grip harness and boot cover to the relay box. MOTORCYCLE S 13 of 15
56. Secure the heated grip harness with the wire tie as MOTORCYCLE S WIRE TIE (wide/short) Secure the heated grip harness to the motorcycle s harness. 59. Connect the heated grip harness as 3-PIN WATERPROOF CONNECTOR (Black) Keep the connected parts in the motorcycle s boot. 57. Route the heated grip harness as 60. Install the front upper cowl in the reverse order of removal. 61. Install the meter panel, right inner cowl and right shroud in the reverse order of removal. 62. Secure the heated grip harness with the wire tie as <Right side> 58. Remove the dummy connector as WIRE TIE (wide/short) Secure the heated grip harness to the right shroud. FRONT UPPER COWL 3-PIN WATERPROOF CONNECTOR (Black) 3-PIN WATERPROOF DUMMY CONNECTOR (Black) (Save) 14 of 15
63. Install the motorcycle s parts in the reverse order of removal. Confirm that no harness is caught or too tight. 64. 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. 65. Check the heated grip, head light and the other lights for proper operation. 15 of 15