INSTALLATION INSTRUCTIONS

Transcription

1 Accessory Application Publication No. INSTALLATION INSTRUCTIONS HARD FRONT DOORS P/N 0SU95-HL SXS700M4/M2 Honda Dealer: Please give a copy of these instructions to your customer. MII Issue Date January 2017 PARTS LIST No. Description Qty (1) (2) (3) (16) Screw, 5 x 16 mm 6 (17) Flat washer, 5 mm 12 (18) Screw, 6 x 16 mm 2 (19) Flat washer, 6 mm 10 (20) Screw, 6 x 20 mm 4 (21) Fender washer, 8 mm 8 (4) (5) (6) (22) Nut, 5 mm 6 (23) Screw, 6 x 25 mm 4 (24) Fender washer, 1/4 inch 4 (25) Locknut, 8 mm 8 (26) Bolt, 8 x 20 mm 8 (7) (8) (9) (27) O-ring 4 (28) Locknut, 12 mm 2 (29) Bolt, 8 x 25 mm 8 (30) Adhesive foam, 1 x 1/8 inch (not shown) 10 ft (10) (11) (16) (17) (31) Adhesive foam, 1-1/2 x inch (not shown) 5 ft (14) (12) (13) (15) (18) (20) (23) (26) (29) (19) (21) (24) (27) (22) (25) (28) TOOLS AND SUPPLIES REQUIRED Hex wrench (4 mm, 5 mm, 6 mm, 8 mm) Wrench (12 mm, 14 mm, 19 mm) Torque wrench Torx driver, T27 No. Description Qty (1) Hard door, left 1 (2) A-pillar panel, left 1 (3) A-pillar bracket, left 1 (4) Hard door, right 1 (5) A-pillar panel, right 1 (6) A-pillar bracket, right 1 (7) Gas cap blockoff 1 (8) Latch bracket, right 1 (9) Latch bracket, left 1 (10) Latch clamp 2 (11) Trim clip 6 TORQUE TABLE 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 Ibf ft 5 mm screw mm screw mm screw Striker bolt (12) A-pillar clamp 2 (13) Hinge-A 2 (14) Striker bolt 2 (15) Hinge-B American Honda Motor Co., Inc - All Rights Reserved. 0SU95-HL of 6

2 USE AND CARE INFORMATION Check the accessory mounts frequently and retighten if necessary. Replace this accessory with a new one if it is damaged or discolored excessively. Never use petroleum solvents such as gasoline, thinner, and benzene, to clean this accessory. Also do not use acid or alkaline cleaners. 2. Remove the front side nets from the cab frame: Release the net buckles, snap hooks and the net straps. Remove the upper two net retainers from each side of the cab frame. UPPER NET RETAINERS Remove and save. NOTICE Installation of this accessory will create the need for more frequent air cleaner maintenance. Service the air cleaner daily when operating in dusty conditions. NOTE If installing a complete cab, install this door kit last. Self-adhesive foam is supplied to install, at the enduser s discretion, at various locations to seal against water, dust, or air ingress. INSTALLATION 1. Remove the original equipment front doors by first opening the door and then removing the four bolts. BOLTS 3. Remove the front side net retainer bolts, side net buckle, and retainer from the A-pillar plate on both sides. Save the socket bolts for reuse later. A-PILLAR PLATE SOCKET BOLTS SIDE NET BUCKLE/ RETAINER 2 of 6 0SU95-HL American Honda Motor Co., Inc - All Rights Reserved.

3 4. Align the right A-pillar bracket with the door holes and loosely install it with four 8 mm fender washers and 8 x 20 mm bolts. A- PILLAR BRACKET 6. Install hinge-b to the bottom hinge location in the A-Pillar Bracket with two 8 x 25 mm bolts and 8 mm locknuts. Align the hinge all the way forward in the slot and tighten the hardware to the specification in the Torque Table. <VIEW FROM OUTSIDE> LOCKNUTS BOLT FENDER WASHER 8 x 25 mm BOLTS HINGE B 5. Install the A-pillar bracket and A-pillar clamp to the A-Pillar with two 6 mm flat washers and 6 x 20 mm screws. Tighten the hardware to the specification in the Torque Table. <VIEW FROM INSIDE> A-PILLAR AR CLAMP FLAT WASHERS 6 x 20 mm SCREWS Hinge must be all the way forward A-PILLAR BRACKET 2013 American Honda Motor Co., Inc - All Rights Reserved. 0SU95-HL of 6

4 7. Install hinge-a into the upper hinge location on the A-pillar bracket with two 8 x 25 mm bolts and 8 mm locknuts. Align the hinge all the way forward in the slots and tighten the hardware to the specification in the Torque Table. 9. Wrap two O-rings around the threaded bosses on the A-Pillar plate. Install two 1/4 inch fender washers and the bolts removed in Step 3 over the O-rings. A-PILLAR PLATE O-RING FENDER WASHER A-PILLAR BRACKET SOCKET BOLTS Reuse HINGE-A 10. Align the right latch bracket on the inside of the weldment on the B-pillar. Install the latch bracket to the weldment with two 6 x 25 mm screws and two 6 mm flat washers. Hinge must be all the way forward 8. Align the right A-Pillar panel with the A-Pillar bracket. Insert three trim clips through the panel and into the bracket. 11. Install the latch clamp to the latch bracket with a 6 x 16 mm screw and 6 mm flat washer. Torque the three mounting screws to the specification in the Torque Table. 6 mm FLAT WASHER WELDMENT 6 x 16 mm LATCH CLAMP SCREW 6 mm FLAT WASHER 6 x 25 mm SCREW TRIM CLIP A-PILLAR PANEL B-PILLAR LATCH BRACKET 4 of 6 0SU95-HL American Honda Motor Co., Inc - All Rights Reserved.

5 12. Loosely install the striker bolt to the latch bracket with an 8 mm locknut. Make sure the striker bolt is centered within the latch bracket slot. LOCKNUT LATCH BRACKET THE FOLLOWING STEPS REQUIRE TWO PEOPLE 14. Mate the lower door hinge, that was removed from the door in Step 13, into hinge-b (installed on the lower position on the A-pillar bracket). Hold up the right door in alignment with the door hinge and loosely install it with the hardware removed in Step 13. STRIKER BOLT 13. Note that the upper and lower door hinges are different, mark them according to their respective locations and remove them from the right hard door. 15. Mate the upper door hinge, that was removed from the door in Step 13, with hinge-a (installed in the upper position on the A-Pillar bracket. Hold up the right door in alignment with the door hinge and loosely install it with the hardware removed in Step 13. HINGE 2013 American Honda Motor Co., Inc - All Rights Reserved. 0SU95-HL of 6

6 Due to the nature of this design, there will be a minimal gap in the upper hinge. HINGE GAP 18. After the door has been adjusted, install the gas cap blockoff onto the right door with five 5 x 16 mm screws, ten 5 mm flat washers, and five 5 mm nuts as shown. <VIEW FROM OUTSIDE> SCREW WASHER NUT 16. With the door hinges loosely installed, adjust the alignment of the door in relation to the cab frame. Tighten all the hinge hardware to the specification in the Torque Table. GAS CAP BLOCKOFF LOWER HINGE UPPER HINGE 19. Repeat Steps 1 through 21 for installation of the left hard door. 20. Use the 1 inch and 1-1/2 inch adhesive foam provided in this kit to fill in any gaps in the fully assembled cab. Tighten bolts/nuts. 17. The vertical position of the striker bolt can be adjusted by moving the striker bolt up/down on the latch bracket. The washer on the striker bolt may also be removed if required for proper fit. Tighten the striker bolt and locknut to the specification in the Torque Chart. STRIKER BOLT WASHER LOCKNUT 6 of 6 0SU95-HL American Honda Motor Co., Inc - All Rights Reserved.