INSTALLATION INSTRUCTIONS
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1 INSTALLATION INSTRUCTIONS Accessory FABRIC REAR DOORS (5P) P/N 0SR90-HL4-211B (BLACK) P/N 0SR90-HL4-211C (CAMO) Application SXS1000M5P/M5D Honda Dealer: Please give a copy of these instructions to your customer. Publication No. MII Issue Date August 2015 PARTS LIST (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (22) (21) (21) (Exterior View) (Interior View) 2015 American Honda Motor Co., Inc - All Rights Reserved. 0SR90-HL4-211B & 211C 1 of 6
2 No. Description Qty (1) Latch knob 2 (2) 6 mm washer 12 (3) 6 x 20 mm pan head bolt 4 (4) 7/16 x 20 TPI Ball end 2 (5) 5/16 inch lock nut 2 (6) 6 mm lock nut 4 (7) 6 x 16 mm pan head bolt 4 (8) 6 x 40 mm bolt 1 (9) 8 mm flange nut 1 (10) Hose clamp 4 (11) Locking hinge 4 (12) Left/Right latch 1 ea. (13) Striker 2 (14) Striker cover 2 (15) Gas spring 2 (16) Latch plate 2 (17) Philips head screw 2 (18) Jacknut 4 (19) Threadlocker 1 (20) Strap 2 (21) Rear door (Left and Right) 2 (22) Rubber pad 4 (23) Installation Instruction URL (not shown) 1 TOOLS AND SUPPLIES REQUIRED Gloves Safety goggles Punch Power drill Drill bit (9.5 mm) Open-end wrench (10 mm, 13 mm) Hex wrench (4 mm, 5 mm) Philips head screwdriver Flat head screwdriver Slip joint pliers Sockets (10 mm, 4 mm hex driver, 6 mm hex driver, Phillips driver) 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. Item N m kgf m lbf ft 6 mm fasteners /16 fasteners /16 x 20 TPI ball end Philips head screw Jacknut Hose clamp USE AND CARE INFORMATION Completely read and understand the instructions before installing this accessory. Do not tow the vehicle on an open trailer with this accessory installed, as the accessory is not designed for use at highway speeds. To clean, sponge with mild soap and cold water, rinse with a hose and allow it to drip-dry. Do not machine wash or dry. Use mild detergent to remove stubborn stains. The window can be rolled up and stowed using the webbing straps and snaps. Do not force the window zipper. In case of a jam, unzip and remove any obstructions. If problems persist, the zipper must be cleaned. The window zipper should be cleaned using a toothbrush with soap and water and rinsed as needed to keep it free of dust and dirt. Once the zipper is cleaned, the teeth should be lubricated using beeswax. When the fabric doors are wet or muddy, the additional weight could cause the door to close unexpectedly. You could be injured if the door closes unexpectedly. Use caution when standing nearby the door while it is in the open position. INSTALLATION 1. Apply threadlocker to threads of the 6 x 16 mm pan head bolts, 6 x 20 mm pan head bolts, and the 7/16 x 20 TPI ball end following the instructions on the packet. 2 of 6 0SR90-HL4-211B & 211C 2015 American Honda Motor Co., Inc - All Rights Reserved.
3 2. Loosely install the latch to the latch plate with the stamped markings up, making sure the opening in the latch lines up with the opening in the latch plate as shown. Install using the 6 x 16 mm pan head bolts and 6 mm washers. Center the bolts in the slots and finger tighten them. Assemble the other latch/plate. 4. Attach the latch plate assembly to the fabric rear door using the 6 mm washers and locknuts. FRAME STUD INSERT FABRIC REAR DOOR 6 x 16 mm PAN HEAD BOLT OPENING 6 mm WASHER 6 mm WASHER LOCKNUT LATCH PLATE PATENTED EBERHARD LATCH 3. Install the strap and latch knob to the latch using the Phillips head screw as shown. Install the latch knob on the same side of the latch as the latch plate, with the strap between the screw and the latch. Use the slip joint pliers to grip the knob and fully tighten the screw to secure the strap and the knob. 5. Loosely install the locking hinges on the upper rear cab frame using the hose clamps and rubber pads as shown. The rubber pad should be installed against the base of the locking hinge. The locking hinge should be installed with the opening facing down and the hinge portion to the inside of the vehicle. The locking hinge should be able to move freely on the cab frame. CAB FRAME LOCKING HINGE LATCH KNOB STRAP HOSE CLAMP PHILLIPS HEAD SCREW CAB FRAME RUBBER PAD LOCKING HINGE 2015 American Honda Motor Co., Inc - All Rights Reserved. 0SR90-HL4-211B & 211C 3 of 6
4 6. Install the rear fabric door to the locking hinges so that the forward hinge is between the two plastic buttons on the door frame as shown. Adjust the hinges so that the door frame is centered inside of the cab frame and the fabric door bottom seal fully contacts the lower door. Tighten the hose clamps once the door is correctly aligned. Be sure that the rubber pads are positioned between the hinges and the cab frame. Do not over tighten the hose clamps. Install and adjust the other door. 7. Remove the original equipment ball end from the body end of the gas spring as shown. Install the 7/16 x 20 TPI ball end (from parts kit) into the the seat belt anchor as shown. Attach the long strap (hanging off the door) onto the ball end by pushing the hole in the end of the strap over the ball as shown. Install the threaded end of the gas spring to the door bracket with a 5/16 inch locknut. Snap the body end end of the gas spring over the ball end. Repeat the above steps on the other door. FABRIC DOOR FRAME BALL END (Remove and discard.) CAB FRAME RUBBER PAD HOSE CLAMP Move spring clip only enough to release the ball end. THREADED END PLASTIC BUTTON LOCKING HINGE 5/16 inch LOCKNUT DOOR BRACKET GAS SPRING SEAT BELT ANCHOR LONG STRAP 7/16 x 20 TPI BALL END (From parts kit.) 4 of 6 0SR90-HL4-211B & 211C 2015 American Honda Motor Co., Inc - All Rights Reserved.
5 8. Temporarily place the striker on top of the closed lower door. Center the latch and latch plate in both sets of slots; swing the fabric door into place and align the striker with the door latch. Close the latch onto the striker. Hold the striker brackets in place while unlatching and opening the fabric door. Mark the top edge of the lower door through the centers of the striker slots as shown. Drill 9.5 mm holes at the marked points on the lower door. Repeat the above steps on the other door. TOP EDGE OF LOWER DOOR DOOR LATCH 9. Install a jacknut into each drilled hole on the lower door: Apply a tapping/cutting or general use oil to the threads of the jacknut. Press the jacknut into the 9.5 mm hole on the top of the door. Align the 8 mm flange nut over the jacknut with the flange down. Thread the 6 x 40 mm bolt into the jacknut, through the flange nut until it is finger tight. Tighten the bolt to the jacknut torque value specified in the Torque Chart. Use a wrench to keep the flange nut from spinning and ensure that the jacknut is seated against the plastic. Remove the bolt. Repeat for each 9.5 mm hole in both doors (two jacknuts total per door). STRIKER 10. Loosely install the striker and cover with two 6 x 20 mm pan head bolts and washers as shown. Remove the striker cover from the striker loop and then close the door and fully tighten the striker hardware. Install the striker and cover on the other door. TOP EDGE OF LOWER DOOR 6 x 20 mm PAN HEAD BOLT STRIKER COVER WASHER Mark drill holes. STRIKER INSTALLED JACKNUT 2015 American Honda Motor Co., Inc - All Rights Reserved. 0SR90-HL4-211B & 211C 5 of 6
6 11. Close the door and adjust the door latch and striker until the fabric door closes and latches consistently. Fully tighten all hardware at this time. Adjust the door latch and striker on the other door. DOOR LATCH STRIKER 6 of 6 0SR90-HL4-211B & 211C 2015 American Honda Motor Co., Inc - All Rights Reserved.
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