Puig Crash Pads R19 Installation Manual for Honda CBR500R (2019-2020)

1. Introduction

This manual provides detailed instructions for the proper installation and maintenance of your Puig R19 Crash Pads, specifically designed for the Honda CBR500R models from 2019 to 2020. These crash pads are engineered to offer integral protection to the chassis and engine of your motorcycle in the event of a fall or slide. Please read these instructions carefully before proceeding with the installation to ensure correct fitment and optimal performance.

2. Safety Information

• Always wear appropriate personal protective equipment (PPE) during installation.
• Ensure the motorcycle is stable and securely supported on a stand before beginning any work.
• Do not overtighten fasteners. Refer to your motorcycle's service manual for specific torque specifications if available.
• If you are unsure about any step of the installation process, consult a qualified motorcycle mechanic.
• Keep all components out of reach of children.

3. Package Contents

Before beginning installation, verify that all components are present and undamaged. The package should contain:

• Puig R19 Crash Pads (Left and Right)
• Mounting hardware (bolts, washers, spacers as per instructions sheet)
• Installation Instructions Sheet (refer to this manual for detailed steps)

Note: The specific components included may vary slightly. Refer to the physical instructions sheet provided in your product packaging for the exact list.

4. Installation Guide

The installation of Puig R19 Crash Pads is designed to be straightforward. Follow these steps carefully:

1. Prepare the Motorcycle: Park the motorcycle on a level surface and secure it using a paddock stand or center stand. Ensure the engine is cool.
2. Identify Mounting Points: Locate the designated mounting points on the motorcycle frame. These are typically existing engine mount bolts. Refer to your motorcycle's service manual or the included instructions sheet for precise locations.
3. Remove Original Bolts (if applicable): Carefully remove the original engine mount bolt(s) from one side of the motorcycle. Work on one side at a time to maintain engine stability.
4. Install Crash Pad Bracket: Attach the appropriate crash pad bracket (if separate from the pad itself) to the frame using the provided hardware. Ensure proper alignment.
5. Mount the Crash Pad: Secure the Puig R19 Crash Pad to the bracket or directly to the frame using the new, longer bolt and any spacers/washers supplied. Hand-tighten initially.
6. Torque Fasteners: Once both sides are loosely installed, ensure everything is aligned. Then, tighten all bolts to the manufacturer's recommended torque specifications. It is crucial not to overtighten.
7. Repeat for Other Side: Follow the same procedure for the opposite side of the motorcycle.
8. Final Check: After installation, double-check all fasteners for tightness and ensure the crash pads are securely mounted and do not interfere with any motorcycle components (e.g., fairings, handlebars, wheels).

Image 1: A pair of Puig R19 Crash Pads. These components are made of nylon and designed to absorb impact, protecting the motorcycle's frame and engine during a fall. The pads feature a robust, angular design in grey and black, with the Puig logo subtly integrated.

5. Operation

Puig R19 Crash Pads are passive safety devices. Once correctly installed, they operate by extending beyond the motorcycle's fairings and engine components, acting as a sacrificial point of contact with the ground during a slide or impact. This design helps to lift the motorcycle slightly off the ground, reducing damage to critical parts such as the frame, engine casings, and fairings. No active operation is required from the rider.

6. Maintenance

• Regular Inspection: Periodically check the crash pads and their mounting hardware for any signs of looseness, damage, or wear. Ensure all bolts remain securely tightened.
• Cleaning: Clean the crash pads with a mild soap and water solution. Avoid harsh chemicals or abrasive cleaners that could damage the material.
• Post-Incident Inspection: After any fall or impact, thoroughly inspect the crash pads and their mounting points. Even if visible damage is minimal, the structural integrity may be compromised. It is highly recommended to replace crash pads that have sustained an impact to ensure continued protection.
• Replacement: If a crash pad is damaged, replace it immediately. Replacement parts may be available through authorized Puig dealers.

7. Troubleshooting

• Crash Pad Feels Loose: Re-check all mounting bolts and ensure they are tightened to the correct torque specifications. If the issue persists, inspect for damaged threads or incorrect installation of spacers.
• Interference with Motorcycle Components: If the crash pads interfere with fairings or other parts, re-check the installation steps. Ensure the correct crash pad is installed on the correct side (left/right) and that all spacers are used as instructed.
• Visible Damage After a Fall: Crash pads are designed to absorb impact. If they show signs of damage (cracks, deep scratches, deformation), they have performed their function. Replace them immediately to ensure continued protection.

For further assistance, please contact Puig customer support or an authorized dealer.

8. Specifications

9. Warranty and Support

Puig products are manufactured to high-quality standards. For information regarding warranty coverage, please refer to the warranty card included with your product or visit the official Puig website. For technical support, replacement parts, or any inquiries, please contact your authorized Puig dealer or Puig customer service directly.

Official Puig Website: www.puig.tv