Issue Date
February 2016
INSTALLATIONINSTRUCTIONS
Accessory Application Publication No.
MII 15641
© 2016 Honda Motor Co., Ltd. - All Rights Reserved.
PARTS LIST
87952-MJP-G5001 of 14
Honda Dealer: Please give a copy of these instructions to your customer.
(1)
TOP CASE (Wave key type)
P/N 08L71-MJP-A60
TOP CASE LOCKSold separately
BACKRESTSold separately
CRF1000L/LD
No. Description Qty
(1) Lock assembly 1
(2) Cam plate 1
(3) Key lock spring 1
(4) 6 mm socket bolt 4
(5) Collar 4
(6) 6 mm square nut 4
(7) Key lock washer 1
No. Description Qty
(1) Backrest 1
No. Description Qty
(1) Top case 1
(2) Installation instruction URL 1
TOP CASE MOUNTSold separately
For the installation, refer to the Installation Instructions.
No. Description Qty
(1) Installation instruction URL 1
(2) Mount base 1
(3) Rubber 4
(4) 8 mm flange bolt 4
(5) Plate 2
(6) Flange collar 8
(7) Washer 4
(8) 8 mm flange nut 4
(6)
(1)
(2)
(3)
(7)
(5)
(4)
(2)
(1)
(5)
(3)
(4)
(6)
(2)
(1)
(7)
(8)
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No. Description Qty
(1) Cylinder body 1
(2) Inner joint 1
(3) Spring plate 1
(4) Washer 1
(5) E-ring 1
No. Description Qty
(1) Inner cylinder 1
(2) No.1 tumbler 6
(3) No.2 tumbler 6
(4) No.3 tumbler 6
(5) No.4 tumbler 6
(6) No.5 tumbler 6
(7) No.6 tumbler 6
(8) Sub-lock tumbler A 1
(9) Sub-lock tumbler B 1
(10) Spring (Silver) 13
(11) Stopper tumbler 2
(12) Stopper spring (Black) 2
(13) Grease 1
(7)(6)
(5)(4)
(3)
(2)
(8) (9) (10)(11)(12)
(13)
(1)
(1)(2) (3)
(4)(5)
• Do not use the slots.
Not used.
TOOLS AND SUPPLIES REQUIREDHex wrench (4 mm)Long nose pliersIsopropyl alcoholShop towelTorque wrench
TORQUE CHARTTighten 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 lbf·ft
6 mm socket bolt 10 1.0 7
MAXIMUM LOADING CAPACITY• The weight of the cargo must not exceed the
following maximum loading capacity:
Maximum Loading Capacity
Top case 6.0 kg (13.2 lb)
1 KEY INNER CYLINDER (Wave key type)Sold separately
1 KEY BODY PARTSSold separately
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< Notes regarding the key cylinder > • This product is used to assemble a key cylinder
matching the motorcycle key by combining six types of tumblers.
• When this key cylinder is installed in a case or similar equipment, the installed equipment can be operated with the motorcycle key.
Combine six types of tumblers.
INNER CYLINDER
No.6
No.3
No.5
No.2
No.4
No.1
INSTALLATIONNOTE:
• 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.
1. The two sub-lock tumbler types shown are provided.• The part has a different slot for each of
the two sub-lock tumbler types.• As the tumblers are small, keep them in the
bag until they are used.
The stopper tumbler will be used later.
No.6 No.5 No.4 No.3 No.2 No.1
2. The six tumbler types shown are provided.• The part has a different width for each of
the six tumbler types.• As the tumblers are small, keep them in the
bag until they are used.
SUB-LOCK TUMBLER A SUB-LOCK TUMBLER B
STOPPER TUMBLER
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Insert tumblers and springs at the shaded positions.
3. Install the tumblers and springs (silver) as shown.• First install four No.1 tumblers.• Note the installed tumbler in the chart below.
Position A Position B Position C Position D
No.1 tumbler
No.2 tumbler
No.3 tumbler
No.4 tumbler
No.5 tumbler
No.6 tumbler
B
A
INNER CYLINDER
C
D
SPRING SIDE
Incorrect. Correct.
TUMBLER
SPRING (Silver)
INNER CYLINDER
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8. Insert a different tumbler(s) at the marked positions.• Start with No. 2 tumblers and continue
sequentially.
6. Press down lightly on the tumbler, pull the key out.• The tumbler spring may jump out when the
tumbler is not pressed down lightly.
7. Pull out the projecting tumbler(s). • Leave the spring(s) installed.
INNER CYLINDER
TUMBLERSPress down lightly.
TUMBLERSPress down lightly.
KEY
TUMBLERProjecting tumbler.
TUMBLER
INNER CYLINDER
INNER CYLINDER
9. Repeat steps 4 to 8, inserting different tumblers at the marked positions until no tumblers are projecting.• Lightly press down on the tumblers from
above, then insert the key.
TUMBLERS
KEY
INNER CYLINDER
5. Confirm that some tumblers are projecting. Mark the positions of the projecting tumblers.• The positions where tumblers project and the
projecting height differ according to the key.
4. Insert the key as shown.• Lightly press down on the tumblers from
above, then insert the key.
Projecting tumbler
Correct.
INNER CYLINDER
TUMBLERSPress down lightly.
TUMBLERSPress down lightly.
KEY
INNER CYLINDER
KEY
TUMBLER
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• Note the installed tumbler to the chart below.
Position E Position F
No.1 tumbler
No.2 tumbler
No.3 tumbler
No.4 tumbler
No.5 tumbler
No.6 tumbler
• Note the installed tumbler to the chart below.
Sub-lock tumbler A
Sub-lock tumbler B
11. Use steps 4 through 8 to assemble the reverse side of the inner cylinder in the same manner.
12. Install the sub-lock tumbler as shown.
Insert sub-lock tumbler and spring at the shaded position.
KEY
TUMBLER
INNER CYLINDER
INNER CYLINDER
SUB-LOCK TUMBLERSPRING (Silver)
SPRING SIDE
INNER CYLINDER
Insert tumblers and springs at the shaded positions.
10. Install the tumblers and springs (silver) to the opposite side of the inner cylinder as shown.• First install two No.1 tumblers.
E
F
INNER CYLINDER
TUMBLER
SPRING (Silver)
SPRING SIDE
INNER CYLINDER
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Insert stopper tumbler and stopper spring at the shaded position.
17. Install the stopper tumbler and stopper spring (black) as shown.
18. Insert the key as shown.• Lightly press down on the tumblers from
above, then insert the key.• Confirm the stopper tumbler is projecting.
INNER CYLINDER
STOPPER SPRING (Black)
STOPPER TUMBLER
SPRING SIDE
STOPPER TUMBLER
INNER CYLINDER
KEY
14. Insert the assembled inner cylinder into the cylinder body as shown.• Confirm the inner cylinder turns clockwise
smoothly.
13. Confirm the sub-lock tumbler is not projecting.• If the tumbler is projecting, change to another
sub-lock tumbler and recheck.
15. Pull out the inner cylinder.
16. Press down lightly on the tumblers and pull out the key.
SUB-LOCK TUMBLER
KEY
INNER CYLINDER
Not projecting.
Not projecting.
KEY
INNER CYLINDER
CYLINDER BODY
INNER CYLINDER
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Confirm the inner joint area is properly aligned as shown.
Push in while turning clockwise.
21. Install the inner cylinder by sliding the stopper tumbler along the slide guide while rotating it.• If the inner cylinder cannot be inserted,
confirm no tumblers, other than the stopper tumbler, are projecting.
22. Pull out the key and check that the inner cylinder does not come out.
GROOVEINNER JOINT
KEY
INNER CYLINDER
CYLINDER BODY
STOPPER TUMBLERSLIDE GUIDE
STOPPER TUMBLER
INNER CYLINDER
Align the tab with the small groove.
19. Apply grease to the shaded areas as shown.• Apply to the inner joint, tumbler and to the
outer circumference of the inner cylinder.• Only use the supplied grease.
20. Install the inner joint into the cylinder body as shown.
INNER CYLINDER
GREASEApply
INNER JOINT
TABCYLINDER BODY
GROOVE (small)
INNER JOINT
INNER JOINT
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Apply grease to the shaded area.
24. Install the spring plate as shown.
SPRING PLATE
KEY CYLINDER SIDE
25. Install the cam plate, washer and e-ring as shown.• Align the projection on the cam plate with the
cutout in the inner joint.
SPRING PLATEAlign the projection.
KEY CYLINDER
LOCK ASSEMBLY
LOCK ASSEMBLY
KEY CYLINDER
WASHER
CAM PLATE
Align.
E-RING
23. Insert the key and attach the assembled key cylinder to the lock assembly as shown.• Only use the supplied grease.
WideNarrow
LOCK ASSEMBLYKEY LOCK WASHER
KEY CYLINDER ASSEMBLYAlign the projection.
LOCK ASSEMBLY
KEY LOCK WASHER
KEY LOCK SPRING
Install the spring while aligning the projection on the key cylinder assembly with the cutout in the lock assembly as shown.
PROJECTION
KEY CYLINDER ASSEMBLY
KEY LOCK SPRING
KEY LOCK WASHERCUTOUT
GREASEApply.
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28. Lower the lever and turn the key counter-clockwise as shown.
29. Open the lid.
LOCK ASSEMBLY
LEVER
LID
TOP CASE
KEYTurn to lock position.
<LOCK>
<UNLOCK>
26. Turn the key and check the key lock system as shown.• If the key lock system is not operational,
reassemble the key cylinder.
27. Install the 6 mm square nuts as shown.
6 mm SQUARE NUTS
LOCK ASSEMBLY
Align the center of the holes.
EACH 6 mmSQUARE NUT
LOCK ASSEMBLY
HOLES
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Hook the lock assembly on the rib of the top case as shown.
30. Install the lock assembly lightly into the top case as shown.
RIB
HOOK
HOLE
LOCK ASSEMBLY
ENDFirst install in the top case.
TOP CASE
TOP CASEHOOK
RIB
31. Secure the lock assembly as shown.
32. Clean the surface of the area shown using isopropyl alcohol.
6 mm SOCKET BOLT
COLLAR
LOCK ASSEMBLY
TOP CASE
BACKREST
6 mm SQUARE NUT
ISOPROPYL ALCOHOLThoroughly clean the area where the backrest will be attached.
33. Peel off the adhesive backing on the inner side of the backrest as shown.
ADHESIVE BACKINGPeel back leaving a little adhered.
ADHESIVE BACKINGPeel back leaving a little adhered.
ADHESIVE BACKINGPeel back leaving a little adhered.
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2. Move the hinge down, then open the lid as shown.
LID
HINGE
USING THE TOP CASE CAUTION
• To prevent burns, allow the engine, exhaust system, radiator, etc., to cool before installing and removing the accessory.
How to Open the Top case1. Operate the lock mechanism as shown and pull the
hinge up.
KEYOpen.
HINGE
KEY
35. Pressing the backrest with the palm of your hand, remove the adhesive backings from the inner side of the backrest and attach the backrest securely.
36. Apply adequate pressure to the attached backrest.
ADHESIVE BACKINGPull out while pressing on the backrest.
ADHESIVE BACKINGPull out while pressing on the backrest.
34. Install the backrest as shown.
TOP CASE
TOP CASE
BACKRESTAlign the backrest with the shape of the top case securely.
BACKREST
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How to Install the Top case mountNOTE:
• The top case mount is required for installation of this accessory.
1. Install the separately sold top case mount using the top case mount installation instrutions.
2. Insert the key as shown and release the lock by turning the key clockwise.
3. Remove the key.• Make sure the lid is locked down securely.
2. Holding the upper part of the hinge, push the hinge down and turn the key counter-clockwise as shown.
HINGE
KEY
KEYClose.
Confirm the key position is as shown.
How to Close the Top case1. Close the lid.
KEYOpen.
LID
KEY
KEYOpen.
KEY
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4. Position the hook of the lock assembly on the top case mount as shown.
3. Insert the retaining tab of the top case into the top case mount with the lever in the raised position as shown.
TOP CASE
LEVER
TOP CASE MOUNT
RETAINING TAB
TOP CASE
HOOK
6. Remove the key. Be sure the lever cannot be released and the top case is installed securely.• The top case can come off while riding if it is
not mounted securely.
5. Secure the hook by pressing the lever down as shown, then lock with the key.
TOP CASE
TOP CASE
HOOKLEVER
LEVER
KEY
KEYClose.
How to Remove the Top case1. Remove the top case in the reverse order of
installation.
TOP CASE MOUNT