R&G CP0485 User manual
Page 1of 47 CP0485
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
FITTING INSTRUCTIONS FOR CP0485
AERO CRASH PROTECTORS
DUCATI V2 2020-
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 47 CP0485
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
TOOLS REQUIRED
•Socket set to include 2.5, 3, 4, 5, 6, 7 & 8mm
A/F socket and wrench.
•Torx head tools
•Socket set to include a deep 8mm & 19mm
socket and wrench.
•8 & 10mm spanner.
•Flat headed screwdriver.
•Torque wrench (up to 40Nm).
•Suitable centre lift stand to support the
chassis during rear suspension removal
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
M0382 LHS CRASH PROTECTOR BRACKET
1
ITEM 2
M0383 RHS CRASH PROTECTOR BRACKET
1
ITEM 3
M0384 RHS ENGINE MOUNT PLATE
1
ITEM 4
EB077 ENGINE BAR
1
ITEM 5
B0431 M12 CRASH PROTECTOR
2
ITEM 6
BC002 BOBBIN CAP
2
ITEM 7
M12 x 1.25 x 100mm HEX HEAD BOLT RHS
1
ITEM 8
M12 x 1.25 x 140mm HEX HEAD BOLT LHS
1
ITEM 9
M12 19MM O/D WASHER
2
ITEM 10
LW0001 SHAKE PROOF WASHER
2
ITEM 11
S0670 9mm SPACER (LHS REAR)
1
ITEM 12
S0735 41.5mm SPACER (RHS FRONT)
1
ITEM 13
S0736 6.5mm SPACER (SHOCK MOUNT)
1
ITEM 14
S1252 23.5mm RHS PANEL SPACER
2
ITEM 15
S0757 3mm RHS PANEL SPACER
2
ITEM 16
S0791 82mm SPACER (LHS CRASH PROTECTOR)
1
ITEM 17
S1251 41mm SPACER (RHS CRASH PROTECTOR)
1
ITEM 18
M8 x 1.25 x 25mm BUTTON HEAD BOLT
2
ITEM 19
M8 x 1.25 x 30mm BUTTON HEAD BOLT
1
Page 3of 47 CP0485
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
ITEM 20
M6 x 1.00 x 20mm BUTTON HEAD BOLT
2
ITEM 21
M6 x 1.00 x 35mm BUTTON HEAD BOLT
1
ITEM 22
M6 x 1.00 x 55mm BUTTON HEAD BOLT
2
ITEM 23
M6 x 1.00 x 65mm BUTTON HEAD BOLT
3
ITEM 24
M6 x 1.00 x 70mm LONG BUTTON HEAD BOLT
2
ITEM 25
M10 x 1.25 x 50mm CAP HEAD BOLT
1
ITEM 26
MP0116 LHS CRASH PROTECTOR BRACE PLATE
1
ITEM 27
MP0117 RHS CRASH PROTECTOR BRACE PLATE
1
ITEM 28
S0792 16.5mm RHS REAR SPACER
1
ITEM 29
S0793 40mm RHS REAR BRACE SPACER
1
ITEM 30
S0794 36.5mm RHS CENTRAL BRACE SPACER
1
ITEM 31
S0795 35mm RHS FRONT BRACE SPACER
1
ITEM 32
M6 STAINLESS NUT
1
ITEM 33
M6 WASHERS 12mm OD x 1mm
2
AERO-STYLE CRASH PROTECTOR ORIENTATION
Page 16 of 47 CP0485
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
FITTING INSTRUCTIONS
PLEASE NOTE THAT BEFORE BEGINNING, YOU WILL NEED A SUITABLE
STAND TO LIFT THE MOTORCYCLE ALLOWING REMOVAL OF THE REAR
SHOCK. DO NOT PROCEED IF YOU ARE NOT COMFORTABLE TO DO THIS.
HAVE FITTED BY A QUALIFIED TECHNICIAN. READ ALL STEPS BEFORE
PROCEEDING.
•Begin by removing RHS belly pan panels by removing the following bolts using
Torx tool and 4mm allen key to remove:
oRow of 3 x Torx bolts along RHS connecting mid fairing to lower fairing,
arrowed in Picture 1.
o2 x 4mm allen bolts underside of belly pan, arrowed in Picture 2.
o1 x 4mm allen bolt on rear mount, arrowed in Picture 3.
o1 x Torx head bolt on inside of front cowl, arrowed in picture 4.
•Next, follow the same procedure to remove the LHS belly panel removing the
following bolts:
oRow of 4 x Torx head bolts along LHS connecting mid fairing to lower
fairing.
o1 x allen bolt underside of belly pan forward 1 bolt (removed in previous
step).
o1 x 4mm Rear mount bolt.
o1 x Torx bolt inside front cowl.
•The key shroud panel must be removed (Picture 5) using a 3mm & 4mm allen
key to remove the following bolts:
o2 x outer 3mm allen keys bolts, arrowed in Picture 6.
o2 x upper 4mm allen head bolts, arrowed in Picture 7.
•Next, remove the RHS inner nose panel (Picture 8) by removing the following
bolts:
o2 x pop rivets inside fairing surrounding radiator, removed by pressing
the centre inwards to release and then removing plastic rivet.
o1 x 3mm allen at front of panel, arrowed in picture 9.
•To remove RHS Mid fairing panel (main section), remove all the bolts listed
below:
o2 x 3mm behind RHS inner nose panel shown in pictures 10 and 11.
o1 x 4mm allen bolt under centre nose cone shown in picture 12.
o2 x 3mm allen bolts, upper rear fairing.
o1 x 3mm allen hidden behind mid fairing accessed from rear, as shown in
picture 13.
At this point the fairing is free to be removed and should be supported at all
times during the next steps.
opry the fairing carefully away from the bike so 3 x plastic pop pins inside
fairing can be accessed and help disengage them from the rubber mounts
as required. DO NOT TRY TO FULLY REMOVE FAIRING.
Page 17 of 47 CP0485
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
oShift the whole fairing panel towards the rear of the bike to disengage the
final pop pin at the top rear of the panel below the fuel tank, as shown in
Picture 14.
•Remove the RHS mid fairing inner panel, shown in picture 15:
oRemove the locking nut from the engine stud at the base of the panel
using an 8mm socket, arrowed in picture 16.
oRemove the upper 3mm allen bolt arrowed in picture 17.
oRemove the forward 4mm bolt found behind the radiator, shown in
picture 18.
oPull the panel section away from the bike and disengage the rubber pop
pin and remove the panel completely.
•Next, the RHS Engine case panel must be removed permanently from the bike.
oFirst remove the 2 x 4mm allen bolts shown in picture 19.
oRemove the two 4mm allen bolts shown in picture 20 & 21.
oRemove the 3mm allen bolt securing the ABS unit in position as shown in
picture 22.
oMove the ABS unit away from the bike as shown in picture 23 to reveal a
3rd allen bolt to be removed, as shown in picture 24. Do not disconnect
any wiring.
oRemove the 2 x 8mm hex nuts shown in pictures 25 & 26, making sure to
remove the retaining spacers also.
oNow the lower engine panel can be removed. Pull the front two mounts
from the studs and carefully remove the brake pressure switch line from
the plastic panel and slide the panel downwards and away from the bike,
as shown in picture 27.
•Now remove the engine case panel mount bracket by removing the two 8mm
engine case bolts, as shown in picture 28. You can re-fit these engine bolts as
originally mounted and re-torque the bolts to the manufactures specified
amount.
•Re-fit the plastic ABS unit, using the original 3mm allen bolt.
•Remove 2 x 8mm shaft nuts arrowed in picture 29 to allow the brake reservoir
panel to be pulled away from the bike and off the engine studs. Do not
remove the panel completely.
•Remove the two studs below the panel using an 8mm deep socket.
•Take the single stepped spacers (item 14 –S1252) and insert into the rearward
holes from behind the plastic hose guide, as shown in picture 30.
•The plastic hose guide should now relocate into place, with both spacers
aligning with the bolt holes in the engine case.
•Fit the small spacer with the smaller diameter centre (item 15 –S0757 –3mm
long) over the exposed smaller step of spacer S0756, as shown in picture 31.
•On all model variants, remove the remaining 8mm head engine case bolt, as
arrowed in picture 32.
•Referring to RHS Assembly Diagram 1, take the right side rearward mounting
plate (item 2 –M0383) and fit one M6 x 55mm long button head bolt (item 22)
through the rearward hole and then through the plastic spacer (item 28 –
Page 18 of 47 CP0485
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
S0792 –16.5mm long). Now fit one M6 washer (item 33), followed by the M6
nut (item 32) and then the remaining M6 washer (item 33), as shown in picture
33.
•Tighten the nut onto the bolt so that it just begins to tighten onto the plastic
spacer.
•Now the RHS rearward mounting plate with the rearward bolt can be offered up
to the bike as shown in picture 34.
•Take the remaining M6 x 55mm long button head bolt (item 22) and place
though the third hole from the rear, locating through the set of spacers already
fitted which secure the rear of the plastic hose guide in place, before loosely
tightening into the engine case, as shown in picture 34.
•To ensure the rear bolt is correctly mounted into the engine case, tighten the
bolt into the casing and then lock it using the M6 nut which is already fitted.
This will allow the plastic spacer to be slightly pinched in place and will help
absorb forces in the event of a crash.
•Re-fit the front 8mm hex head bolt cap to secure the front of the plastic hose
guide in place and relocate any wiring connectors that were previously un-
mounted.
•Remove the engine case bolt from behind the hydraulic hose, as arrowed in
picture 35.
•Referring to RHS Assembly diagram 2, offer the right side forward mounting
plate (item 3 –M0384) into place, ensuring the large hole locates over the
threaded boss of the previously installed mounting plate, before fitting one M6 x
65mm long button head bolt (item 23) through the top mounting hole, then the
other mounting plate and spacers before loosely tightening into the engine case
as shown in picture 36.
•Take the long spacer (item 12 –S0735 –41.5mm long) and position it between
the mounting plate and engine case in alignment with the front mounting hole,
before inserting the M6 x 70mm long button head bolt (item 24) and loosely
tightening, as shown in picture 37.
•With all four mounting bolts now in place and the 2 mounting plates correctly
mounted, tighten the bolts to the manufacturers recommended torque settings,
as shown in picture 38.
•From the left side of the bike, insert the engine bar (item 4 –EB077 –
252.5mm long) behind the rear cylinder, allowing the other end to locate with
the remaining hole on the right-side mounting plate. Please note insert the
engine bar so that the end with the 8mm spanner flats sits on the left side of
the bike, as shown in picture 39.Fit one M6 x 20mm long button head bolt
(item 20) through the mounting plate and loosely tighten into the engine bar.
Page 19 of 47 CP0485
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
The next steps will require removal of the LHS upper and mid fairing and entails
similar process to the steps performed for the RHS fairing:
•Remove the LHS inner nose panel (picture 8) by removing the following bolts:
o2 x pop rivets inside fairing surrounding radiator, removed by pressing
the centre inwards to release and then removing plastic rivet.
o1 x 3mm allen at front of panel (picture 9).
•Remove the LHS upper fairing panel in the same method as the RHS by
removing:
o2 x 3mm allen bolts, upper rear fairing
o2 x 3mm behind LHS inner nose panel (RHS shown in pictures 10 and 11)
o1 x 4mm allen head bolt, top. (previously hidden behind key shroud
removed earlier)
o1 x 3mm allen hidden behind mid fairing accessed from rear (as shown in
picture 13)
o1 x pop rivet to inner nose cone
oAt this point the fairing is free to be removed and should be
supported at all times during the next steps.
oPry the fairing carefully away from the bike so 3 x plastic pop pins inside
fairing can be accessed and help disengage them from the rubber mounts
as required. DO NOT TRY TO FULLY REMOVE FAIRING.
oShift the whole fairing panel towards the rear of the bike to disengage the
final pop pin at the top rear of the panel below the fuel tank as shown in
picture 14.
•Remove the LHS mid fairing inner panel:
oRemove the locking nut from the engine stud at the base of the panel
using an 8mm socket, arrowed in picture 40.
oRemove the forward 4mm bolt found behind the radiator as shown in
picture 41.
oPull the panel section away from the bike and disengage the rubber pop
pin and remove the panel completely.
•The regulator/ rectifier mounting panel should be moved to access upper
suspension mount:
oRemove 2 x 4mm black cap bolts shown in pictures 42 & 43.
•The motorcycle now needs to be mounted onto a suitable stand which supports
the bike from the swingarm pivot to allow for the rear suspension to be
removed, as shown in picture 44. The rear wheel will also need to be supported
to prevent it from dropping when the shock absorber is removed.
•Remove the 3 x allen bolts securing the plastic shock cover.
•Remove the two bolts which secure the shock absorber in place using an 8mm
allen key, as shown in picture 45, and remove the shock from the bike
completely.
•With the shock absorber removed, remove the three bolts which secure the
front mounting plate in place to the rear cylinder head, as shown in picture 46.
•Remove the engine case bolt which sits near the previously installed engine bar
and above the rear shock linkage, as shown in picture 47.
Page 20 of 47 CP0485
R&G Racing
Unit 1, Shelley’s Lane, East Worldham, Alton, Hampshire, GU34 3AQ
•Take the left side mounting plate (Item 1 –M0382) and offer it up to the bike
as shown in picture 48. Insert one M8 x 25mm long button head bolt (Item 18)
through the front hole of the mounting plate and into the threaded boss on the
side of the cylinder head, also shown in picture 48.
•On the top mounting hole, place the M8 x 30mm long button head bolt (item
19) through the mounting plate, then through the short spacer (item 13 –
S0736 –6.5mm long) and loosely tighten into the thread boss on the side of
the rear cylinder head, as shown in picture 49.
•Fit the remaining M8 x 25mm long button head bolt (item 18) into the
remaining hole, above the threaded boss.
•At the rear of the mounting plate, fit the M6 x 35mm long button head bolt
(item 21) through the mounting plate hole, then through the small spacer (item
11 –S0670 –9mm long) and loosely tighten into the engine case, as shown in
picture 50.
•The previously fitted engine bar should now be in a location where it can align
with the remaining hole on the mounting plate. Fit the remaining M6 x 20mm
long button head bolt (item 20) and loosely tighten into the engine bar, as
shown also in picture 50.
•With the mounting plate correctly mounted it should look like picture 51.
Tighten all the bolts to the manufacturers recommended torque settings. For
the bolt that tightens into the engine bar, hold the engine bar in place using an
8mm open ended spanner on the flats of the bar, whilst tightening the button
head bolt, as shown in picture 39. Please ensure to tighten the button head
bolt on the other end of the engine bar as well.
•Re-fit the shock absorber to the bike using the OEM bolt on the rear mount but
using the M10 x 1.25 x 50mm long 10.9 grade cap head bolt supplied in the kit
(item 25) on the front mount. When fitting, first place through the recessed
OEM spacer and then fit through the smaller hole of the left brace plate (item
26 –MP0116) so that the bend in the plate comes out from the bike, as shown
in pictures 52 & 53. Tighten this loosely, so that the brace can still be
moved.
•The LHS crash protector can now be fitted. Referring to LHS Assembly
Diagram 1 and following the steps below:
oSlide one of the 12mm washers (item 9) onto the M12 x 1.25 x 140mm
long hex head bolt (item 8) so the washer sits against head of bolt.
oSlide one shake proof washer (item 10) over the bolt so it sits against the
washer just fitted.
oNext slide the bolt with washers through either crash protector (item 5)
so the head of the bolt and washers goes into counter-bore in the bobbin.
oLocate the longer crash protector spacer (item 16 –S0791 –82mm long)
over the exposed end of the bolt, ensuring the larger diameter end sits
against the crash protector, as shown in picture 54.
oOffer the crash protector up to the mounting plate by locating the spacer
through the larger hole in the left brace plate and tighten the bolt into the
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