INSTALLATION INSTRUCTIONS

Transcription

1 Accessory Application Publication No. INSTALLATION INSTRUCTIONS FOG LAMP ATTACHMENT P/N 08V70-MJR-640 GL1800C MII Issue Date January 2014 PARTS LIST No. Description Qty ((( Right bracket 1 (1) (2) ((( Left bracket 1 ((( Fog lamp switch 1 ((( Fog lamp harness 1 ((( Wire tie (narrow) 10 ((( 6 mm bolt 2 ((( Fog lamp stay 2 ((( Collar (long) 6 ((( Collar (short) 3 (((( Grommet 6 (((( Flange collar 6 (3) (5) (10) (((( Washer (large) 6 (((( 6 mm flange bolt (short) 3 (((( 6 mm flange bolt (long) 5 (8) (14) (12) (11) (9) (((( 6 mm flange nut 4 (((( Spring washer 4 (((( Washer (small) 4 (((( 6 mm screw 4 (23) (((( Wire tie (wide) 2 (((( Plate 2 (((( 6 mm socket bolt 4 (20) (((( Connector cover 1 (((( Double-side adhesive tape 1 (((( URL paper 1 (21) (13) (22) (((( Sub harness 1 (((( 3 mm screw 2 (25) (15) FRONT LED FOG LAMP Sold separately (19) (6) (18) (1) (7) (17) (16) (2) (26) (4) (24) No. Description Qty ((( Front LED fog lamp 2 ((( Front LED fog lamp driver Honda Motor Co., Ltd. - All Rights Reserved. 1 of MJR-6402

2 TOOLS AND SUPPLIES REQUIRED Socket (10 mm) Ratchet Box-end wrench (10 mm) Open-end wrench (10 mm) Hex wrench (4 mm) Phillips screwdriver Nippers Scale Electrical tape Scissors File Isopropyl alcohol Shop towel 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 Ibf ft 6 mm screw mm socket bolt mm flange bolt and nut INSTALLATION CAUTION To prevent burns, allow the engine, exhaust system, radiator, etc., to cool before installing the accessory. Be sure to observe all safety messages and precautions described in the Service Manual while removing and installing the fuel tank. NOTE: The Front LED fog lamp is required for installation of this accessory. 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 memories of the clock will be erased when you disconnect the battery. Reset the memories 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. When working with lifting the fuel tank, always perform this work with two personas; it is recommended that one person lifts the tank. 1. Remove the pillion seat as shown. PILLION SEAT COLLAR BOLT 2 of 19

3 2. Remove the main seat as shown. 5. Remove the waterproof dummy connector as shown. MAIN SEAT BOLT MOTORCYCLE S 2-PIN WATERPROOF CONNECTOR (Black) 2-PIN WATERPROOF DUMMY CONNECTOR (Black) (Save) 3. Remove the left side cover, and disconnect the negative (-) cable from the battery. Repeat on the right side. <Left side> 6. Connect the sub harness as shown. MOTORCYCLE S 2-PIN WATERPROOF CONNECTOR (Black) 2-PIN WATERPROOF CONNECTOR (Black) SUB HARNESS 4. Open the box cover as shown. <Right side> LEFT SIDE COVER When you are also installing the Accessory Socket SUB HARNESS 2-PIN WATERPROOF CONNECTOR (Black) 2-PIN WATERPROOF DUMMY CONNECTOR (Black) (Save) ACCESSORY SOCKET HARNESS BOX COVER 3 of 19

4 7. Connect the fog lamp harness as shown. 9. Connect the fog lamp harness as shown. SUB HARNESS 3-PIN WATERPROOF CONNECTOR (Green) FRONT LED FOG LAMP DRIVER 4-PIN WATERPROOF CONNECTOR (Black) 2-PIN WATERPROOF CONNECTOR (Black) 10. Install the front LED fog lamp driver as shown. 8. Attach the double-side adhesive tape to the front LED fog lamp driver as shown. DOUBLE-SIDED ADHESIVE TAPE Remove the adhesive backing of the double-side adhesive tape before attaching. FRONT LED FOG LAMP DRIVER Align with the top face. Do not protrude from the frame. FRONT LED FOG LAMP DRIVER FRONT LED FOG LAMP DRIVER Remove the adhesive backing of the double-side adhesive tape before attaching. ISOPROPYL ALCOHOL Thoroughly clean the area where the double-sided adhesive tape will be attached. ISOPROPYL ALCOHOL Thoroughly clean the area where the front LED fog lamp driver will be attached. 4 of 19

5 11. Remove the 18-pin waterproof connector as shown. MOTORCYCLE S HARNESS 13. Store the sub harness and the harness boot in the indicated position. SUB HARNESS 18-PIN WATERPROOF CONNECTOR (Black) HARNESS BOOT Store the just connected 4-pin waterproof connector (Black) in the harness boot. 12. Route the 18-pin waterproof connector as shown. 18-PIN WATERPROOF CONNECTOR (Black) When you are also installing the Accessory Socket SUB HARNESS ACCESSORY SOCKET HARNESS HARNESS BOOT Store the just connected 4-pin waterproof connector (Black) and accessory socket harness in the harness boot. 14. Connect the 18-pin waterproof connector. 5 of 19

6 15. Remove the front upper cowl as shown. 17. Remove the clips as shown. Repeat on the right side. CLIP CLIP CLIP CLIP SCREW FRONT UPPER COWL 18. Cut out the front lower cowl as shown. Remove the any burrs from the edge of the hole. 16. Remove the front lower cowl as shown. NIPPERS Cut out. FRONT LOWER COWL SCREW FILE File off the cutout surface. FRONT LOWER COWL SCREW 6 of 19

7 19. Remove the left radiator side panel as shown. Repeat on the right side. <Left side> Remove the fuel lid cable to the key cylinder. FUEL LID CABLE 20. Remove the left shroud cover as shown. Repeat on the right side. WASHER SCREW LEFT RADIATOR SIDE PANEL (BACKSIDE) SCREW KEY CYLINDER Left side only. LEFT SHROUD COVER SCREW 21. Remove the left inner cowl as shown. Repeat on the right side. CLIP LEFT RADIATOR SIDE PANEL BOLT LEFT INNER COWL 7 of 19

8 22. Remove the fuel lid cover as shown. FUEL LID COVER SCREW 24. Remove the wire from the tank cap as shown. FUEL LID INNER COVER SCREW WIRE TANK CAP 23. Remove the fuel lid inner cover as shown. Remove the fuel lid cable to the fuel lid inner cover. FUEL LID INNER COVER 25. Remove the indicated bolts. BOLT WASHER FUEL LID CABLE CLIP 26. Raise the fuel tank as shown. CLIP FUEL TANK FUEL LID INNER COVER 8 of 19

9 27. Route the fog lamp harness as shown. 30. Move the left radiator as shown. LEFT RADIATOR 28. Secure the fog lamp harness as shown with a wire tie. 31. Route the fog lamp harness as shown. WIRE TIE (narrow) Secure the fog lamp harness to the motorcycle s harness. FOG LAMP HARNESS RADIATOR HOSE 29. Remove the bolts as shown. <Left side> BOLT 9 of 19

10 32. Secure the fog lamp harness as shown with a wire tie. 35. Secure the fog lamp harness as shown with a wire tie. WIRE TIE (narrow) Secure the fog lamp harness to the motorcycle s harness. LEFT RADIATOR 33. Return the fuel tank to its original position. 34. Route the fog lamp harness as shown. <Front side> WIRE TIE (narrow) Secure the fog lamp harness to the motorcycle s harness. 36. Install the left radiator in the reverse order of removal. 37. Install the grommets in the holes of the left bracket as shown. Repeat on the right side. LEFT BRACKET GROMMET LEFT RADIATOR 10 of 19

11 38. Install the flange collars to the left bracket as shown. Repeat on the right side. 40. Loosely install the front LED fog lamp to the left bracket as shown. Repeat on the right side. LEFT BRACKET LEFT BRACKET 6 mm SCREW SPRING WASHER FRONT LED FOG LAMP FLANGE COLLAR WASHER (small) 39. Install the fog lamp stay to the front LED fog lamp as shown. Install the remaining fog lamp stay in the same way. 6 mm BOLT FRONT LED FOG LAMP FOG LAMP STAY 6 mm FLANGE NUT 11 of 19

12 41. Loosely install the bolt as shown. Tighten the loosely install bolt and 6 mm screws securely after ADJUSTING THE FOG LAMP AIMING. <Left side> COLLAR (long) 42. Route the left front LED fog lamp harness as shown and install the plate to the left bracket. Repeat on the right side. TEMPORARILY ASSEMBLED LEFT BRACKET 6 mm FLANGE NUT COLLAR (long) LEFT BRACKET FRONT LED FOG LAMP 6 mm FLANGE BOLT (long) 6 mm SCREW LEFT FRONT LED FOG LAMP HARNESS Pass the left front LED fog lamp harness between the collars. PLATE <Right side> COLLAR (long) 6 mm SOCKET BOLT 6 mm FLANGE BOLT (long) 43. Remove the bolts as shown. <Right side> BOLT (Save) 6 mm FLANGE NUT RIGHT BRACKET 6 mm SCREW FRONT LED FOG LAMP 12 of 19

13 44. Install the right front LED fog lamp as shown. RIGHT FRONT INNER LOWER COVER (Reuse) 45. Secure the right front LED fog lamp harness in the position shown. RIGHT FRONT LED ASSEMBLED RIGHT FRONT LED FOG LAMP WASHER (large) 6 mm FLANGE BOLT (short) RIGHT FRONT LED COLLAR (large) WIRE TIE (narrow) Secure the right front LED fog lamp harness to the collar (large). 46. Route the right front LED fog lamp harness as shown. CLAMP (Reuse) Secure the right front LED fog lamp harness to the motorcycle s harness. RIGHT FRONT LED 13 of 19

14 47. Secure the right front LED fog lamp harness in the position shown. 49. Install the left front LED fog lamp as shown. LEFT FRONT INNER LOWER COVER (Reuse) MOTORCYCLE S WIRE TIE (Reuse) Secure the right front LED fog lamp harness and motorcycle s harness to the stay. STAY RIGHT FRONT LED 48. Remove the bolts as shown. <Left side> BOLT (Save) WASHER (large) 6 mm FLANGE BOLT (long) COLLAR (short) ASSEMBLED LEFT FRONT LED FOG LAMP 14 of 19

15 50. Secure the left front LED fog lamp harness in the position shown. 52. Connect the left front LED fog lamp harness to the fog lamp harness as shown. LEFT FRONT LED FOG LAMP HARNESS COLLAR (large) WIRE TIE (narrow) Secure the left front LED fog lamp harness to the collar (large). 2-PIN WATERPROOF CONNECTOR (White) / CODE (Blue, Gray) LEFT FRONT LED 53. Secure the left front LED fog lamp harness and fog lamp harness as shown with a wire tie. WIRE TIE (wide) Bundle the left front LED fog lamp harness and secure it to the motorcycle s harness. LEFT FRONT LED MOTORCYCLE S HARNESS LEFT FRONT LED 51. Route the left front LED fog lamp harness as shown. LEFT FRONT LED LEFT FRONT LED 15 of 19

16 54. Connect the right front LED fog lamp harness to the fog lamp harness as shown. 2-PIN WATERPROOF CONNECTOR (White) / CODE (White, Blue) 56. Remove the dummy cap as shown. SCREW (Save) DUMMY CAP (Save) LEFT RADIATOR SIDE PANEL 2-PIN WATERPROOF CONNECTOR (Black) RIGHT FRONT LED 57. Turn over the connector cover as shown. 55. Secure the fog lamp harness in the position shown. CLAMP (Reuse) Secure the fog lamp harness and the motorcycle s harness. CONNECTOR COVER RIGHT FRONT LED 16 of 19

17 58. Cut the connector cover as shown. CONNECTOR COVER 60. Pass the connector cover over the fog lamp switch harness as shown. CONNECTOR COVER Cut four places as dimensions shown. FOG LAMP SWITCH HARNESS 61. Install the fog lamp switch as shown. 5 mm 5 mm 3 mm SCREW Discard. 7.5 mm 7.5 mm 3 mm SCREW Cut. 3 mm FOG LAMP SWITCH 3 mm LEFT RADIATOR SIDE PANEL (Reuse) 59. Return the connector cover and cut it as shown. CONNECTOR COVER 25 mm SCISSORS 17 of 19

18 62. Fit the connector cover as shown. CONNECTOR COVER 64. Wind the connector cover with electrical tape as shown. ELECTRICAL TAPE CONNECTOR COVER FOG LAMP SWITCH 63. Secure the connector cover with the wire ties as shown. CONNECTOR COVER 65. Install the left inner cowl and left shroud cover in the reverse order of removal. 66. Connect the fog lamp switch harness as shown, and install the left radiator side panel in reverse order of removal. <Left side> 3-PIN WATERPROOF CONNECTOR (Blue) WIRE TIE (narrow) Secure the connector cover to the fog lamp switch. FOG LAMP SWITCH FOG LAMP SWITCH HARNESS LEFT RADIATOR SIDE PANEL Wind tape around the fog lamp switch harness as shown. ELECTRICAL TAPE FOG LAMP SWITCH HARNESS 18 of 19

19 67. Connect the negative (-) cable to the battery and check each light for function. 68. Perform the ADJUSTING THE FOG LAMP AIMING. 69. Install the motorcycle s parts in reverse order of the removal. Confirm that any wire harness is not caught or too tight. ADJUSTING THE FOG LAMP AIMING 1. Place the motorcycle on a level surface, 5 m away from the aiming screen. Turn on the fog lamps. 2. Measure the mounting height of the fog lamp from the floor. 3. Aim the fog lamps so that the cut-off line of the light pattern on the aiming screen is the some distance above the floor as the fog lamp mounting height. MOUNTING HEIGHT of FOG LAMP 5 m CUT-OFF LINE MOUNTING HEIGHT of FOG LAMP 19 of 19