1 | Bolt (4) |
2 | Washer (4) |
1. | See Figure 2. Apply masking tape to the outside painted surface of the fender at hole locations (2 and 3). This will protect the painted surface during the drilling operation. | |||||||
2. | Put the fender on a work bench, painted surface down. Use clean, soft cloth between the fender and the work bench to protect the paint finish. NOTE Drilling each hole in the fender is a two-step procedure that requires a specific type of drill bit to avoid damaging the fender. | |||||||
3. | Use a 1/2-inch spade bit or 1/2-inch unibit (do not use a spiral-type drill bit) to drill hole(s) from the inside of the fender through the pilot hole boss(es). Stop drilling when the bit pierces the outside surface of the fender. | |||||||
4. | Turn the fender over so the painted surface is now facing up. Complete each hole by using the same 1/2-inch drill bit at each of the pierced hole(s). Clean excess material from the hole(s) and clean the fender surface of any debris. | |||||||
5. | Remove the masking tape from the hole(s). |
Figure 2. Inside of Fender | ||||||
6. | See Figure 5. Install the upright (1) onto the rubber gasket (I). | |||||||
7. | See Figure 3. Put the upright upside down on the work bench and align the holes with the holes in the fender. | |||||||
8. | Align the mounting holes of the support bracket (H) with the mounting holes of the upright. | |||||||
9. | See Figure 5. Install bolt (2) and tighten finger-tight. | |||||||
10. | Install the two screws (E) and nuts (A) in the outer mount locations and tighten finger-tight. | |||||||
11. | Verify proper alignment of all components and then tighten the two screws to 7–9 N·m (62–80 in-lbs). | |||||||
12. | Tighten bolt (2) to 10–12 N·m (88–106 in-lbs). | |||||||
13. | Proceed to Final Installation - All Assemblies. |
1 | Luggage rack |
2 | Fender |
1 | Carriage bolt (2) |
2 | Flange nut (2) |
1. | See Figure 2. Apply masking tape to the outside painted surface of the fender at hole locations (1, 2 and 3). This will protect the painted surface during the drilling operation. | |
2. | Put the fender on a work bench, painted surface down. Use clean, soft cloth between the fender and the work bench to protect the paint finish. NOTE Drilling each hole in the fender is a two-step procedure that requires a specific type of drill bit to avoid damaging the fender. | |
3. | Use a 1/2-inch spade bit or 1/2-inch unibit (do not use a spiral-type drill bit) to drill hole(s) from the inside of the fender through the pilot hole boss(es). Stop drilling when the bit pierces the outside surface of the fender. | |
4. | Turn the fender over so the painted surface is now facing up. Complete each hole by using the same 1/2-inch drill bit at each of the pierced hole(s). Clean excess material from the hole(s) and clean the fender surface of any debris. | |
5. | Remove the masking tape from the hole(s). | |
6. | If luggage rack has not been previously installed: See Figure 5. Apply the protective tape (L) to the painted surface using the drilled holes for alignment. | |
7. | See Figure 5. Slide the upright (1) onto the luggage rack (K). | |
8. | See Figure 3. Put the luggage rack/upright assembly upside down on the work bench and align the holes in the luggage rack with the holes in the fender. | |
9. | Align the mounting holes of the support bracket (H) with the mounting holes of the upright and luggage rack. | |
10. | See Figure 5. Install screw (D) and tighten finger-tight. | |
11. | Install bolt (2). Tighten finger-tight. | |
12. | Install the two screws (J) in the forward mount locations and tighten finger-tight. | |
13. | Verify proper alignment of all components and then tighten the three screws (D and J) to 7–9 N·m (62–80 in-lbs) | |
14. | Tighten bolt (2) to 10–12 N·m (88–106 in-lbs). | |
15. | Proceed to Final Installation - All Assemblies. |
1. | Install the tail lamp following the instructions in the appropriate service manual. | |
2. | Align the holes in the fender with the holes in the frame. | |
3. | See Figure 4. Install the carriage bolts (1) through the slots on the support bracket and the frame. Install the flange nuts (2) and tighten finger-tight. | |
4. | See Figure 5. Install two screws (F) and flat washers (G) through the holes in the seat pan and into the weld nuts on the support bracket (H). Tighten finger-tight. | |
5. | Verify alignment and position of the fender. | |
6. | See Figure 1. Install four fender mounting bolts (1) and washers (2). Tighten to 20–26 N·m (15–19 ft-lbs). | |
7. | See Figure 5. Tighten the nuts (C) and screws (F) to 7–9 N·m (62–80 in-lbs). |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Upright assembly | Not Sold Separately |
| 51605-09 | |
| 51611-09 | |
| 51612-09 | |
| 51646-09 | |
| Not Sold Separately | |
2 | Bolt | Not Sold Separately |
Items mentioned in text, but not included in kit: | ||
Upright mounting kit (51607-09 - purchased separately) | ||
A |
| |
B |
| |
C |
| |
E |
| |
F |
| |
G |
| |
H |
| |
I |
| |
Luggage rack kit (53315-09 - purchased separately) | ||
B |
| |
C |
| |
D |
| |
F |
| |
G |
| |
H |
| |
J |
| |
K |
| |
L |
| |
M |
| |
Hardware service kit (54230-09 - purchased separately) | ||
A |
| |
B |
| |
C |
| |
D |
| |
E |
| |
F |
| |
G |
| |
J |
| |
M |
|