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Installation of SW-MOTECH Quick-Lock sideracks on the Honda 919 / CB900 Hornet

Posted on July 27, 2004 by TwistedThrottle.com There have been 0 comments

Here we have an installation tutorial fitting the SW-Motech sideracks on a Honda CB919.
Here's an overview of the installation process for setting up your Honda 919 with sideracks from SW-MOTECH. I took these photos of Kevin Bray's Honda 919 when we loaned us his bike for demonstration purposes at the 2003 Dealernews Dealer Expo in Indianapolis, Indiana. Thanks for the chance to show off our stuff Kevin!

NOTE: SW-MOTECH Quick-Lock sidecase racks should be installed BEFORE installing the SW-MOTECH Alu-Rack toprack.

Recommended tools:
o 5mm, 6mm, and 10 mm allen keys
o 4mm bent (90 degree angle) allen key
o 8mm and 10mm socket wrench
o Pliers
o Philips head and flat head screwdrivers
o Drill with 1/4" and 3/8" drill bits (only required for early-model sideracks)
o Medium-strength threadlock compound

Take inventory of all parts, comparing the contents of your package to the parts list in the manufacturer's installation diagram BEFORE beginning the installation process.



(1) Remove the seat from the motorcycle.



(2) Remove rear passenger peg protector bolts.

Using a 5mm allen key and 10mm socket wrench, remove the two bolts holding each of the two passenger peg protectors in place.



(3) Remove rear passenger peg protectors

Remove the black wire passenger peg protector, silver cover, and rubber pad from the frame of the motorcycle.



(4) Install passenger peg luggage mounting points

Install the left passenger peg luggage mounting point as shown using the included replacement bolts and the original 10mm nuts. Do not fully tighten these bolts until step 26. Repeat for the right passenger peg.

Note: Right and left passenger peg mounting points are tapered in opposite directions. If a peg mounting point does not seem to fit into the frame of the motorcycle, try using it on the opposite side of the motorcycle.



(5) Remove sissy bar

Remove the four 6mm allen bolts securing the sissy bar to the motorcycle, then lift the sissy bar off of the motorcycle.



(6) Remove rear fairing bolts

Remove the rubber caps from each of the two rear fairing bolts, then remove the bolts using a 10mm socket wrench.



(7) Remove rear fairing plastic connectors

Remove two plastic connectors (one on each side of the motorcycle) from the rear fairing.



(8) Remove the rear fairing and stoplight bulbs

Remove the rear fairing. Be careful not to pull out the stoplight wires, which are still attached to the fairing. Remove each of the two stoplight bulbs from the rear fairing by rotating each bulb counterclockwise, then pulling it out of the slot.



(9) Remove top rear fender attachment bolts

Remove the two top rear fender attachment hex bolts using an 8mm socket wrench.



(10) Remove side rear fender attachment bolts

Remove the two sideways rear fender attachment bolts using a 4mm bent allen key.



(11) Remove rear fender

Be careful to not pull the license plate light or indicator light wires out of the fender.



(12) Disconnect light wires from junction box

Disconnect the indicator light wires and license plate light wires from the junction box at the rear of the motorcycle. In order to disconnect a wire from the junction box, use a small flat head screwdriver to open the connector clip, then pull out the connector.



(13) Remove the license plate light attachment screws

Remove the two screws that attach the license plate light assembly to the rear fender. The license plate light assembly should now detach from the rear fender.



(14) Remove nuts from interior of license plate light

Remove two 8mm nuts from the interior of the license plate light assembly. The license plate light should now detach from the black plastic light holder.




(15) Install turn signal relocation bracket

Place the turn signal relocation bracket between the license plate light and the black plastic light holder. The bent tips of the turn signal relocation bracket should point toward the front of the motorcycle. Reattach the license plate light to the black plastic light holder using the original nuts and bolts.



(16) Relocate turn signals

Remove the turn signals from their original locations on the fender using a 10mm socket wrench. Reinstall the turn signals on the SW-Motech turn signal relocation bracket. The picture shows the right turn signal in its original position and the left turn signal in its relocated position.



(17) Reinstall rear fender and light wires

Reattach the rear fender to the motorcycle using the two original 4mm allen bolts and two original 8mm hex bolts. Once the fender is reinstalled, reconnect the turn signal wires and license plate light wires to the junction box. When reattaching the indicator wires, remember that the left indicator wire and connector are both orange.



(18) Push electrical junction box into rear frame pocket

Push the electrical junction box into the pocket in the center of the rear frame of the motorcycle.



(19) Reinstall the stoplights and rear fairing

Reattach the two stoplight bulbs to the rear fairing by putting each bulb in its socket and rotating it clockwise. Reinstall the rear fairing using the original hardware. Turn signal wires will now be located between the rear fender and the rear fairing.



(20) Place sissybar and spacers onto bike

Place the sissybar back into its original location above the rear fairing. Place the four steel cylindrical spacers above the bolt holes on the sissybar.



(21) Install luggage rack mounting points onto sissybar

Place the black luggage rack mounting point on top of the steel spacers described in the last step. Place a washer over each of the two bolt holes on the black luggage rack mounting point. Note that the flat side of the black luggage rack mounting points should face up. Attach the sissybar and luggage rack mounting point assembly to the motorcycle using four SW-Motech replacement bolts (allen head). Do not fully tighten these bolts yet.



(22) Install quicklocks onto sidecase racks

Push three quicklocks into each of the two sidecase racks.



(23) Press a retaining washer onto each quicklock to prevent the quicklock from falling out of the luggage rack.



(24) Attach sidecase racks to motorcycle

Attach each of the two sidecase racks to the motorcycle using the two quicklocks on the sissybar and passenger peg mounting points.



(25) Remove the license plate and license plate bracket

Remove the two bolts holding the license plate onto the license plate mounting bracket. Remove the two bolts holding the license plate mounting bracket onto the rear fender.



(26) Position the luggage rack's rear crossbar & tighten remaining mounting points

Position the luggage rack's rear crossbar where the license plate mounting bracket used to be. Attach the rear crossbar to the sidecase racks using the two rear quicklocks. Once the rear crossbar is attached to the sidecase racks, tighten the screws attaching the sissybar and passenger peg mounting points to the motorcycle. Use of threadlock is strongly recommended.



(27) Drill two 1/4" holes in rear fender

This step is not necessary on later revisions of the SW-MOTECH Quick-Lock sideracks as the design was modified in 2004 to accomodate U.S. license bolt patterns (the product was originally prototyped in Germany).

Locate the outermost two holes on the rear luggage rack crossbar. Using these two holes as a guide, drill two 1/4" holes into the rear fender as shown. These holes will be used to bolt the rear crossbar onto the rear fender.



(28) Bolt the rear luggage rack crossbar onto the fender

Use the included SW Motech 10mm nut, 10 mm bolt, and washer to attach the rear luggage rack crossbar to the fender. The washer should be placed between the bolt head and the crossbar as shown.



(29) Reinstall license plate bracket

Position the original license plate bracket above the rear luggage rack crossbar and below the license plate light as shown. If installing the original version of the sideracks, mark the location of the two bolt holes in the license plate bracket that are used to attach the bracket to the fender. Drill a 3/8" hole through the fender at each of the two marked points, then reattach the license plate bracket to the fender using the original hardware and the two new 3/8" holes. If installing the 2004 version of the sideracks, no drilling is necessary.



(30) Attach the license plate to the license plate mounting bracket

Using the original hardware, attach the license plate to the license plate bracket. When complete, the rear of the bike should appear as shown. You're finished!

Honda 919 with SW-MOTECH Quick-Lock sidecase racks attached.

7 seconds later, the Honda 919 with SW-MOTECH Quick-Lock sidecase racks removed from the bike.

This post was posted in SW-MOTECH Bags-Connection