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