Issue DateINSTALLATIONINSTRUCTIONS

Publication No.

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

© 2013 American Honda Motor Co., Inc - All Rights Reserved. 0SU95-HL4-104 1 of 6

ApplicationAccessory

PARTS LIST

(4)

(7)

(1) (2)

(5)

(8) (9)

(3)

(6)

(10)

(12)

(11)

(13)

(14)

(15)

(16)

(18)

(20)

(23)

(26)

(29)

(17)

(19)

(21)

(24)

(27)

(25)

(28)

(22)

No. Description Qty

(1) Hard door, left 1

(2) A-pillar panel, left 1

(3) A-pillar bracket, left 1

(4) Hard door, right 1

(5) A-pillar panel, right 1

(6) A-pillar bracket, right 1

(7) Gas cap blockoff 1

(8) Latch bracket, right 1

(9) Latch bracket, left 1

(10) Latch clamp 2

(11) Trim clip 6

(12) A-pillar clamp 2

(13) Hinge-A 2

(14) Striker bolt 2

(15) Hinge-B 2

HARD FRONT DOORSP/N 0SU95-HL3-104

2014-2016SXS700M4/M2

MII 14607

January 2017

No. Description Qty

(16) Screw, 5 x 16 mm 6

(17) Flat washer, 5 mm 12

(18) Screw, 6 x 16 mm 2

(19) Flat washer, 6 mm 10

(20) Screw, 6 x 20 mm 4

(21) Fender washer, 8 mm 8

(22) Nut, 5 mm 6

(23) Screw, 6 x 25 mm 4

(24) Fender washer, 1/4 inch 4

(25) Locknut, 8 mm 8

(26) Bolt, 8 x 20 mm 8

(27) O-ring 4

(28) Locknut, 12 mm 2

(29) Bolt, 8 x 25 mm 8

(30) Adhesive foam, 1 x 1/8 inch (not shown) 10 ft

(31) Adhesive foam, 1-1/2 x 0.625 inch (not shown) 5 ft

TOOLS AND SUPPLIES REQUIREDHex wrench (4 mm, 5 mm, 6 mm, 8 mm)

Wrench (12 mm, 14 mm, 19 mm)

Torque wrench

Torx driver, T27

TORQUE TABLETighten 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 Ibf·ft

5 mm screw 5.7 .57 4

6 mm screw 9.6 .97 7

8 mm screw 23 2.35 17

Striker bolt 88 8.99 65

© 2013 American Honda Motor Co., Inc - All Rights Reserved.2 of 6 0SU95-HL4-104

USE AND CARE INFORMATION• Check the accessory mounts frequently and

retighten if necessary.

• Replace this accessory with a new one if it is damaged or discolored excessively.

• Never use petroleum solvents such as gasoline, thinner, and benzene, to clean this accessory. Also do not use acid or alkaline cleaners.

NOTICE• Installation of this accessory will create the need for

more frequent air cleaner maintenance. Service the air cleaner daily when operating in dusty conditions.

NOTE• If installing a complete cab, install this door kit last.• Self-adhesive foam is supplied to install, at the end-

user’s discretion, at various locations to seal against water, dust, or air ingress.

INSTALLATION

1. Remove the original equipment front doors by first opening the door and then removing the four bolts.

BOLTS

2. Remove the front side nets from the cab frame:

• Release the net buckles, snap hooks and the net straps.

• Remove the upper two net retainers from each side of the cab frame.

UPPER NET RETAINERSRemove and save.

3. Remove the front side net retainer bolts, side net buckle, and retainer from the A-pillar plate on both sides. Save the socket bolts for reuse later.

SOCKETBOLTS

SIDE NET BUCKLE/ RETAINER

A-PILLAR PLATE

© 2013 American Honda Motor Co., Inc - All Rights Reserved. 3 of 60SU95-HL4-104

4. Align the right A-pillar bracket with the door holes and loosely install it with four 8 mm fender washers and 8 x 20 mm bolts.

A- PILLAR BRACKET

BOLTFENDER WASHER

5. Install the A-pillar bracket and A-pillar clamp to the A-Pillar with two 6 mm flat washers and 6 x 20 mm screws. Tighten the hardware to the specification in the Torque Table.

A-PILLAR CLAMPARAAAAA

FLAT WASHERS

6 x 20 mm SCREWS

6. Install hinge-B to the bottom hinge location in the A-Pillar Bracket with two 8 x 25 mm bolts and 8 mm locknuts. Align the hinge all the way forward in the slot and tighten the hardware to the specification in the Torque Table.

LOCKNUTS

8 x 25 mmBOLTS

HINGE B

Hinge must be all the way forward

A-PILLAR BRACKET

<VIEW FROM INSIDE>

<VIEW FROM OUTSIDE>

© 2013 American Honda Motor Co., Inc - All Rights Reserved.4 of 6 0SU95-HL4-104

7. Install hinge-A into the upper hinge location on the A-pillar bracket with two 8 x 25 mm bolts and 8 mm locknuts. Align the hinge all the way forward in the slots and tighten the hardware to the specification in the Torque Table.

Hinge must be all the way forwardway fo

8. Align the right A-Pillar panel with the A-Pillar bracket. Insert three trim clips through the panel and into the bracket.

TRIM CLIP

A-PILLAR PANEL

9. Wrap two O-rings around the threaded bosses on the A-Pillar plate. Install two 1/4 inch fender washers and the bolts removed in Step 3 over the O-rings.

FENDER WASHER

SOCKET BOLTSReuse

O-RINGA-PILLAR PLATEPLAPPPPPPPPPPP T

10. Align the right latch bracket on the inside of the weldment on the B-pillar. Install the latch bracket to the weldment with two 6 x 25 mm screws and two 6 mm flat washers.

11. Install the latch clamp to the latch bracket with a 6 x 16 mm screw and 6 mm flat washer. Torque the three mounting screws to the specification in the Torque Table.

6 x 25 mm SCREW

WELDMENT

LATCH BRACKET

6 x 16 mm SCREW6 mm FLAT

WASHER DMEDDDDDDDDDD NT

mm W

LATCH CLAMP

6 mm FLAT WASHERHERHHH

A-PILLAR BRACKET

HINGE-A

B-PILLAR

© 2013 American Honda Motor Co., Inc - All Rights Reserved. 5 of 60SU95-HL4-104

12. Loosely install the striker bolt to the latch bracket with an 8 mm locknut. Make sure the striker bolt is centered within the latch bracket slot.

LOCKNUT

STRIKER BOLT

13. Note that the upper and lower door hinges are different, mark them according to their respective locations and remove them from the right hard door.

THE FOLLOWING STEPS REQUIRE TWO PEOPLE

14. Mate the lower door hinge, that was removed from the door in Step 13, into hinge-B (installed on the lower position on the A-pillar bracket). Hold up the right door in alignment with the door hinge and loosely install it with the hardware removed in Step 13.

15. Mate the upper door hinge, that was removed from the door in Step 13, with hinge-A (installed in the upper position on the A-Pillar bracket. Hold up the right door in alignment with the door hinge and loosely install it with the hardware removed in Step 13.

LATCH BRACKETC BBBBB

HINGE

© 2013 American Honda Motor Co., Inc - All Rights Reserved.6 of 6 0SU95-HL4-104

Due to the nature of this design, there will be a minimal gap in the upper hinge.

HINGE GAP

16. With the door hinges loosely installed, adjust the alignment of the door in relation to the cab frame. Tighten all the hinge hardware to the specification in the Torque Table.

LOWER HINGE UPPER HINGE

Tighten bolts/nuts.

17. The vertical position of the striker bolt can be adjusted by moving the striker bolt up/down on the latch bracket. The washer on the striker bolt may also be removed if required for proper fit. Tighten the striker bolt and locknut to the specification in the Torque Chart.

WASHER

18. After the door has been adjusted, install the gas cap blockoff onto the right door with five 5 x 16 mm screws, ten 5 mm flat washers, and five 5 mm nuts as shown.

SCREW WASHER NUT

GAS CAP BLOCKOFF

19. Repeat Steps 1 through 21 for installation of the left hard door.

20. Use the 1 inch and 1-1/2 inch adhesive foam provided in this kit to fill in any gaps in the fully assembled cab.

STRIKER BOLTEEEEEE OLOCKNUT

<VIEW FROM OUTSIDE>