R&G CP0204BL Fitting Instructions

FITTING INSTRUCTIONS FOR CP0204BL/WH CRASH PROTECTORS
P
LEASE NOTE THAT THE WAY THE KIT IS PACKED DOES NOT NECESSARILY REPRESENT THE WAY OF MOUNTING TO THE BIKE
Please note that in cases where kits are packed with rubber washers holding the components onto the bolt – the
rubber washers should be thrown away!
For 2009 model please see latter part of document
2007-2008 models only
Offside (right side as you sit on the bike)
PLEASE NOTE THAT THE EXISTING ENGINE BOLT ON THIS SIDE CAN SOMETIMES BE
HARD TO REMOVE. WE RECOMMEND THAT YOU USE A VERY HIGH QUALITY HEX
DRIVE BIT OR HAVE YOUR LOCAL DEALER INSTALL THE KIT.
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Loosen right-side engine bolt from the bike located in the middle of the castellated adjuster nut (do not remove the
castellated adjuster nut) This is made easier by loosening the fairing, (there is no need to remove it completely)
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Replace the fairing and secure with all of the necessary screws
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Pull the bolt out until it touches the fairing, and mark the position on the edge of the fairing.
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Carefully start to cut the fairing on your mark, using a Dremel tool or similar, until the hole is large enough to
allow the OEM bolt to be removed.
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Take one of the R&G bolts and place a washer behind the head followed by a shake proof washer
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Pass the bolt through the crash protector
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Offer the assembly to the bike and where the neck of the protector touches the fairing draw around it with a pencil.
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Remove the assembly from the bike.
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Using a Dremel tool or similar, gradually cut the fairing until the hole is large enough to accept the neck of the
crash protector
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When you are happy with the hole (it will not be totally round), deburr the edges
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Place the R&G castellated spacer on the end of the bolt, with the teeth facing away from the protector
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Install R&G components, ensuring that the lugs on the castellated spacer face towards the bike and locate over the
grooves on the existing adjuster nut, Note the large diameter of the protector faces towards the front of the bike
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Tighten bolt until you feel some compression from inside the protector. Turn a little more so that you feel the
compression increase slightly. Then apply a quarter turn. Do not over tighten as damage can occur to the bike.
Do not exceed 40nm of torque.
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When happy that everything is correct, place the blanking cap into the end of the protector.
Unit 5K, Blacknest Industrial Park, Blacknest Road, Alton, Hampshire, GU34 4PX
Tel: +44 (0)870 220 6380 Fax: +44 (0)1420 521101
KAWASAKI ZX6R '07-'09
R&G Racing
www.rg-racing.com Email: info@rg-racing.com