HONDA GL1800B-BD Trunk Kit Installation Guide

HONDA GL1800B-BD Trunk Kit

Accessory

• TRUNK INSTALLATION KIT P/N 08L73-MKC-A10ZA.

Application

• GL1800B/BD

Honda Dealer: Please give a copy of these instructions to your customer.

PARTS LIST

TOOLS AND SUPPLIES REQUIRED

• Socket (10 and 12 mm)
• Ratchet
• Hex wrench (5 mm)
• Phillips screwdriver
• 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.

MAXIMUM LOADING CAPACITY

• The weight of the cargo must not exceed the following maximum loading capacity:

Maximum Loading Capacity

Trunk| 20.0 lb (9.0 kg)

INSTALLATION

CAUTION

• To prevent burns, allow the engine, exhaust system, radiator, etc., to cool before installing the accessory.

NOTE:

• 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 memory of 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.

1. Open the left saddlebag lid as shown.
   • Repeat on the right side.
2. Remove the left side cover as shown, and disconnect the negative (-) cable of the battery.
3. Remove the right side cover in the same manner as the left side.
4. Remove the seat as shown.
5. Remove the fuse holders as shown.
6. Remove the left pillion step holder cover as shown.
   • Repeat on the right side.
7. Remove the right and left rear top lid as shown.
8. Remove the parts as shown.
9. Remove the center rear top cover as shown.
10. Remove the rear cross plate as shown.
11. Remove the clips as shown.
12. Remove the right and left passenger grip as shown.
13. Remove the rear fender as shown.
14. Remove the saddlebag rear center cowl as shown.
15. Remove the parts as shown.
    • Repeat on the right side.
16. Remove the screw as shown.
    • Repeat on the right side.
17. Move the left saddlebag and remove the left luggage stay as shown.
    • Repeat on the right side.
18. Remove the screws as shown.
19. Move the right saddlebag catch and remove the plug as shown.
20. Install the emergency trunk cable as shown.
21. Route the emergency trunk cable as shown.
22. Remove the radio antenna as shown.
23. Install the emergency trunk cable as shown.
24. Install the radio antenna and right saddlebag catch in the reverse order of removal.
25. Install the stay as shown.
    • Confirm that any wire harness is not caught or too tight.
    • Repeat on the right side.
26. Install the right and left saddlebag, saddlebag rear center cowl and rear fender in the reverse order of removal.
27. Install the screw grommets as shown.
28. Connect the speaker as shown.
29. Install the speaker as shown.
30. Install the left side speaker in the same manner as the right side.
31. Install the spring nut as shown.
32. Install the right rear speaker cover as shown.
33. Install the clip as shown.
34. Install the spring nut as shown.
35. Install the trunk right front cover as shown.
36. Install the left rear speaker cover and trunk left front cover in the same manner as the right side.
37. Install the trunk sub assembly as shown.
38. Install the emergency trunk cable to the trunk catch as shown.
39. Install the trunk catch as shown.
40. Connect the trunk catch harness as shown.
41. Install the trunk open switch as shown.
42. Connect the 2P black connector and install the trunk center lower cover as shown.
43. Remove the dummy connector as shown.
44. Connect the connector as shown.
45. Remove the dummy connector as shown.
46. Connect the connector as shown.
47. Install the right trunk side cover as shown.
    • Repeat on the left side.
48. Install the 5 mm tapping screws as shown.
    • Repeat on the left side.
49. Install the clips as shown.
    • Repeat on the left side.
50. Install the trunk front lower panel as shown.
51. Install the 5 mm tapping screws as shown.
52. Install the trunk lid as shown.
53. Close the trunk lid.
54. Route and secure the trunk sub harness as shown.
55. Connect and install the backrest as shown.
56. Install the 5 mm tapping screws as shown.
    • Refer to the motorcycle Owner’s Manual and use the emergency trunk cable to open the trunk lid.
57. Install the 5 mm tapping screw as shown.
    • Repeat on the right side.
58. Attach the label as shown.
59. Install the motorcycle’s parts in the reverse order of removal.
    • Confirm that any wire harness is not caught or too tight.
60. Check the speaker, trunk open switch, headlight and the other lights for proper operation.

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