1 | Bolt (4) |
2 | Washer (4) |
1. | See Figure 2. Apply masking tape to the outside painted surface of the fender at the three hole locations (1 and 2). 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. | See Figure 2. Use a 1/2-inch spade bit or 1/2-inch unibit (do not use a spiral-type drill bit) to drill three holes from the inside of the fender through the three pilot hole bosses (1 and 2). Stop drilling when the tip of the bit just 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 holes. Clean excess material from the holes and clean the fender surface of any debris. | |||||||||||||
5. | See Figure 5. Remove the masking tape from the holes and apply the protective tape (3) to the painted surface using the drilled holes for alignment. | |||||||||||||
6. | See Figure 3. Put the luggage rack (1) upside down on the work bench and align the holes in the luggage rack with the holes in the fender (2). | |||||||||||||
7. | See Figure 5. Insert spacers (4) in the forward mount locations in the fender. | |||||||||||||
8. | Align the luggage rack bracket (1) with the spacers. Install screws (6) and tighten finger-tight. | |||||||||||||
9. | Install the two screws (5) in the forward mount locations and tighten finger-tight. | |||||||||||||
10. | Verify proper alignment of all components and then tighten the three screws to 7–9 N·m (62–80 in-lbs). | |||||||||||||
11. | Install the tail lamp following the instructions in the appropriate service manual. | |||||||||||||
12. | Align the holes in the fender with the holes in the frame. | |||||||||||||
13. | See Figure 4. Install the carriage bolts (1) through the slots on the luggage rack bracket and the frame. Install the flange nut (2) and tighten finger-tight. | |||||||||||||
14. | See Figure 5. Install two screws (10) and flat washers (9) through the holes in the seat pan and into the weld nuts on the luggage rack support bracket (1). Tighten finger-tight. | |||||||||||||
15. | Verify alignment and position of the fender. | |||||||||||||
16. | See Figure 1. Install four fender mounting bolts (1) and washers. Tighten to 20–26 N·m (15–19 ft-lbs). | |||||||||||||
17. | See Figure 5. Tighten the nuts (8) and screws (10) to 7–9 N·m (62–80 in-lbs). |
Figure 2. Inside of Fender
Figure 3. Align Luggage Rack and Fender
Figure 4. Install Carriage Bolts |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Bracket | Not Sold Separately |
2 | Luggage rack | Not Sold Separately |
3 | Protective tape | 53737-09 |
Hardware Kit (includes items 4 through 10) | 54230-09 | |
4 | Spacer (2) | Not Sold Separately |
5 | Screw, M6 x 30 mm (2) | Not Sold Separately |
6 | Screw, M6 x 25 mm | Not Sold Separately |
7 | Carriage bolt, M6 x 16 mm (2) | Not Sold Separately |
8 | Flange nut, M6 (2) | Not Sold Separately |
9 | Washer, M6 (2) | Not Sold Separately |
10 | Screw, M6 x 16 mm (2) | Not Sold Separately |