R&G CP0482 User manual

Page 1of 18 CP0482
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
Tel: [phone] Fax: [phone] www.rg-racing.com Email: in[email protected]
FITTING INSTRUCTIONS FOR CP0482
AERO CRASH PROTECTORS (DRILL KIT FOR RACE USE)
KAWASAKI NINJA 400-
THIS KIT CONTAINS THE ITEMS PICTURED AND LABELLED OVER PAGE.
SOME PARTS MAY BE SHOWN FOR CLARITY OF INSTRUCTIONS ONLY.
DO NOT PROCEED UNTIL YOU ARE SURE ALL PARTS ARE PRESENT.
PLEASE READ ALL INSTRUCTIONS BEFORE PROCEEDING.
IF IN ANY DOUBT WHEN FITTING OUR PRODUCTS, CONSULT ONE OF OUR DEALERS
OR HAVE FITTED BY A QUALIFIED TECHNICIAN.
PLEASE NOTE THAT THE WAY THE KIT IS PACKED DOES NOT NECESSARILY REPRESENT THE WAY OF
MOUNTING TO THE BIKE.
IN THE EVENT OF RUBBER WASHERS BEING USED TO HOLD COMPONENTS ONTO BOLTS,
THESE RUBBER WASHERS CAN BE THROWN AWAY.
DIGITAL COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FROM:
WWW.RG-RACING.COM

Page 2of 18 CP0482
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
Tel: [phone] Fax: [phone] www.rg-racing.com Email: in[email protected]
TOOLS REQUIRED
•Dremel + cutting wheel
•28mm hole saw or similar
•17mm socket + ratchet
GENERAL TORQUE SETTINGS
M4 BOLT = 8Nm
M5 BOLT = 12Nm
M6 BOLT = 15Nm
M8 BOLT = 20Nm
M10 BOLT = 40Nm
M12 BOLT = 40Nm
LEGEND
ITEM NO.
DESCRIPTION
QTY
ITEM 1
B0472 10mm CRASH PROTECTOR
2
ITEM 2
BOBBIN CAP
2
ITEM 3
S0672 57mm RHS MOUNT SPACER
1
ITEM 4
S1065 90.5mm LHS MOUNT SPACER
1
ITEM 5
M10 x 1.25 x 150mm LONG HEX BOLT LHS
1
ITEM 6
M10 x 1.25 x 120mm LONG HEX HEAD BOLT RHS
1
ITEM 7
S0451 3.5mm SPACER
1
ITEM 8
M10 19mm OD WASHER
2
ITEM 9
LW0001 SHAKE PROOF WASHER
2
AERO-STYLE CRASH PROTECTOR ORIENTATION

Page 3of 18 CP0482
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
Tel: [phone] Fax: [phone] www.rg-racing.com Email: in[email protected]
RHS ASSEMBLY DIAGRAM 1
LHS ASSEMBLY DIAGRAM 1

Page 4of 18 CP0482
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
Tel: [phone] Fax: [phone] www.rg-racing.com Email: in[email protected]
FITTING PICTURES
Picture 1
Picture 2
FITTING INSTRUCTIONS
PLEASE NOTE THIS KIT IS MEANT TO BE FITTED IN CONJUNCTION WITH
RACE FAIRINGS WHICH MAY REQUIRE MODIFICATION TO FIT THE CRASH
PROTECTOR KIT.
•Remove fairing from the bike so that the forward engine mounts are exposed.
•Support the underside of the engine so that the engine cannot move within the
frame when engine bolts are replaced.
•With the engine supported from underneath, remove the RHS engine bolt from
the frame arrowed in Picture 1.
•To determine where to cut the fairing to accommodate the crash protector,
insert a marking tool into the engine mount hole so that it is level.
•Re-fit the fairing and press the fairing into the marking tool so that a mark is
made on the inside of the panel. This will act as a centre guide when modifying
the fairing.
•Use a drill to make a pilot hole in marked position, followed by a drill bit or hole
saw to enlarge the hole so it is big enough for the M10 engine bolt to pass
through.
•With fairing re-fitted, slide one crash protector over the longer bolt included
with this kit and insert into the fairing hole to engage with the RHS frame
mount, do not tighten, this will detail where the fairing will need to be cut to
accommodate the crash protector. Ensuring the crash protector is completely
level, use a marker or pen to draw around the crash protector to be cut.
•Use a Dremel or similar cutting tool to trim the outline of the fairing and
remove.

Page 5of 18 CP0482
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
Tel: [phone] Fax: [phone] www.rg-racing.com Email: in[email protected]
•Ensure to follow the steps below before repeating the process on the LHS of the
bike. DO NOT REMOVE BOTH LHS AND RHS ENGINE BOLTS AT THE SAME
TIME.
•Referring to RHS Assembly Diagram 1 follow the steps below:
oSlide the small spacer (item 7 –S0451 –3.5mm) onto the M10 x 1.25 x
120mm long hex head bolt (item 6).
oSlide one of the 10mm (item 8) washers over the bolt so the washer sits
against the spacer.
oSlide one shake proof washer (item 9) over the bolt so it sits against the
washer just fitted.
oNext slide the bolt with washers through either crash protector (item 1)
so the head of the bolt and washers goes into counter-bore in the bobbin.
oLocate the shorter crash protector spacer (item 3 –S0672 –57mm long)
over the exposed end of the bolt.
oOffer the crash protector up to the bike by locating the bolt into the RHS
frame mount so the crash protector sits into the crash protector cut out.
oTighten the bolt until you feel some compression from inside the protector
using a 17mm socket and wrench. Please note, the crash protector
must be positioned as aero-style crash protector orientation
diagram on page 2, with bigger end toward front of bike.
oTurn 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.
•Remove the LHS engine bolt arrowed in picture 2.
•Repeat the marking and trimming process for the LHS fairing.
•The LHS crash protector can now be fitted. Referring to LHS Assembly
Diagram 1and following the steps below:
oSlide the remaining 10mm washer (item 8) onto the M10 x 1.25 x 150mm
long hex head bolt (item 5) so the washer sits against head of bolt.
oSlide the remaining shake proof washer (item 9) over the bolt so it sits
against the washer just fitted.
oNext slide the bolt with washers through the remaining crash protector
(item 1) so the head of the bolt and washers goes into counter-bore in
the bobbin.
oLocate the longer crash protector spacer (item 4 –S1065 –90.5mm long)
over the exposed end of the bolt.
oOffer the crash protector up to the bike by locating the bolt into the LHS
frame mount so the crash protector sits into the crash protector cut out.
oTighten the bolt until you feel some compression from inside the protector
using a 17mm socket and wrench. Please note, the crash protector
must be positioned as aero-style crash protector orientation
diagram on page 2, with bigger end toward front of bike.
oTurn 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.

Page 6of 18 CP0482
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
Tel: [phone] Fax: [phone] www.rg-racing.com Email: in[email protected]
•Ensure all fairings are correctly fitted with all bolts fully tightened.
•Fit crash protector caps (item 2) into both crash protectors.
•Before riding, check both sides are secure, and the crash protectors cannot
rotate.
•Check tightness of each side regularly.
ISSUE 1 04/03/2020 (DM)
CONSUMER NOTICE
The catalogue description and any exhibition of samples are only broad indications of the Products and
R&G may make design changes which do not diminish their performance or visual appeal and supplying
them in such state shall conform to the order. The Buyer acknowledges no representation or warranty
(other than as to title) has been given or will apply to the Products other than those in R&G’s order or
confirmation and the Buyer confirms it has chosen the Products as being of merchantable quality and
suitable for its particular purposes. Where R&G fits the Products or undertakes other services it shall
exercise reasonable skill and care and rectify any fault free of charge unless the workmanship has been
disturbed. The Buyer is responsible for ensuring that the warranty on the motorcycle is not affected by
the fitting of the Products. On return of any defective Products R&G shall at its option either supply a
replacement or refund the purchase money but shall not be liable if the Products have been modified or
used or maintained otherwise than in accordance with R&G’s or manufacturer’s instructions and good
engineering practice or if the defect arises from accident or neglect. Other than identified above and
subject to R&G not limiting its liability for causing death and personal injury, it shall not be liable for
indirect or consequential loss and otherwise its liability shall be limited to the amounts paid by the
Buyer for the Products or the fitting or service concerned. These terms do not affect the Buyer’s
statutory rights.
R&G RACING RETURNS POLICY (NON-FAULTY GOODS)
Returns must be pre-authorised (if not pre-authorised the return will be rejected). Goods may only be
returned direct to us if they were purchased direct from us (customer must prove if necessary).
Otherwise to be returned to original vendor. Goods must be in re-sellable condition, in the opinion of
R&G Racing. All returns are subject to a 25% restocking and handling fee (25% of the gross value exc.
P&P –at the prevailing price at time of purchase). The customer must pay any and all carriage
charges. No returns of discontinued products, unless within 14 days of purchase. This policy does not
affect your statutory rights and does not refer to faulty goods.

Page 7of 18 CP0482
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
Tel: [phone] Fax: [phone] www.rg-racing.com Email: [e-mail]
NOTICE DE MONTAGE POUR CP0482
PROTECTIONS CRASH (KIT PERÇAGE POUR UTILISATION PISTE)
KAWASAKI NINJA 400-
LE KIT CONTIENT LES ARTICLES EXPOSES CI-DESSOUS,VERIFIER QUE TOUTES LES PIECES SOIENT PRESENTES AVANT DE PROCEDER AU
MONTAGE.
LES PARTIES PRESENTÉES PEUVENT ETRE UNIQUEMENT REPRESENTATIVES POUR LA CLARTE
DES INSTRUCTIONS UNIQUEMENT.
NE PAS PROCEDER AU MONTAGE TANT QUE VOUS N'ETES PAS SUR QUE TOUTES LES PIECES SOIENT
PRESENTES.
LIRE LES INSTRUCTIONS AVANT DE COMMENCER.
EN CAS DE DOUTE LORS DU MONTAGE DE NOS PRODUITS, CONSULTEZ UN DE NOS
REVENDEURS OU FAITES FAIRE L’INSTALLATION PAR UN TECHNICIEN QUALIFIÉ.
LA FAÇON DONT LE KIT EST EMBALLE NE CORRESPOND PAS FORCEMENT A LA FAÇON DE MONTER LES
PIECES SUR LA MOTO.
AU CAS OU DES RONDELLES EN CAOUTCHOUC SONT UTILISEES POUR MAINTENIR LES COMPOSANTS SUR
LES BOULONS,CES RONDELLES PEUVENT ETRE JETEES.
NOTICE DISPONIBLE AU TELECHARGEMENT SUR : WWW.RG-RACING.COM

Page 8of 18 CP0482
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
Tel: [phone] Fax: [phone] www.rg-racing.com Email: [e-mail]
OUTILS REQUIS
•Dremel + Roue de coupe
•Scie trou 28mm ou similaire
•Clé à cliquet + douille 17mm
VALEURS DE SERRAGE
M4 BOULON = 8Nm
M5 BOULON = 12Nm
M6 BOULON = 15Nm
M8 BOULON = 20Nm
M10 BOULON = 40Nm
M12 BOULON = 40Nm
LÉGENDE
ARTICLE
NO.
DESCRIPTION
QTÉ
ARTICLE 1
B0472 10mm PROTECTION CRASH
2
ARTICLE 2
CAPUCHON DE BOBINE
2
ARTICLE 3
S0672 57mm ENTRETOISE DE SUPPORT CÔTÉ DROIT
1
ARTICLE 4
S1065 90.5mm ENTRETOISE DE SUPPORT CÔTÉ GAUCHE
1
ARTICLE 5
M10 x 1.25 x 150mm BOULON CÔTÉ GAUCHE
1
ARTICLE 6
M10 x 1.25 x 120mm BOULON CÔTÉ DROIT
1
ARTICLE 7
S0451 3.5mm ENTRETOISE
1
ARTICLE 8
M10 19mm RONDELLE
2
ARTICLE 9
LW0001 RONDELLE ANTI-VIBRATION
2
PROTECTION CRASH LATÉRALE

Page 9of 18 CP0482
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
Tel: [phone] Fax: [phone] www.rg-racing.com Email: [e-mail]
SCHÉMA CÔTÉ DROIT 1
SCHÉMA CÔTÉ GAUCHE 1

Page 10 of 18 CP0482
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
Tel: [phone] Fax: [phone] www.rg-racing.com Email: [e-mail]
PHOTOS DU MONTAGE
Picture 1
Picture 2
NOTICE DE MONTAGE
VEUILLEZ NOTER QUE CE KIT EST CONÇU POUR ÊTRE MONTÉ EN
CONJONCTION AVEC DES CARÉNAGES DE COURSE QUI POURRAIENT
NÉCESSITER UNE MODIFICATION POUR S'ADAPTER AU KIT DE PROTECTION
CRASH.
•Retirez le carénage de la moto de façon à ce que les supports de moteur avant
soient exposés.
•Soutenez le dessous du moteur afin que le moteur ne puisse pas se déplacer
dans le cadre lorsque les boulons du moteur sont remplacés.
•Le moteur étant soutenu par le dessous, retirez le boulon moteur côté droit du
cadre, voir photo 1.
•Pour déterminer où couper le carénage pour accueillir la protection crash,
insérez un outil de marquage dans le trou du support moteur de façon à ce qu'il
soit de niveau.
•Remontez le carénage et enfoncez le carénage dans l'outil de marquage de
sorte qu'une marque soit faite à l'intérieur du panneau. Cela servira de guide
central lors de la modification du carénage.
•Utilisez une perceuse pour faire un trou pilote à l’endroit marqué, puis une
mèche ou une scie trou pour agrandir le trou afin qu'il soit suffisamment grand
pour que le boulon moteur M10 puisse passer.
•Une fois le carénage réinstallé, faites glisser la protection crash sur le boulon
plus long inclus avec ce kit et insérez-le dans le trou de carénage pour engager
avec le support de cadre côté droit, ne serrez pas, cela détaillera l’endroit où le
carénage devra être coupé pour accueillir la protection crash. Assurez-vous que