Introduction

This tutorial explains how to fit a decorative metal radiator cover to the Honda CB600F Hornet, replacing the original black plastic one. The photo shows what mine looks like when fitted. There are other kinds available but they will all fit in the same way, so don't worry if yours is a different design. These instructions should still apply.

There is nothing in this guide which cannot be easily undone, so your original grill can easily be refitted if necessary.

Requirements

Warnings

• I have read some reports that radiator covers like this can lead to overheating problems due to the slightly reduced airflow. In my experience this does not appear to be the case. I have been using this grill since 2001 and have noticed absolutely no difference in the running temperature of the bike. However, if you tend to keep the bike in the lower gears with the engine running at higher speeds then it will need all the cooling it can get, and you might notice the temperature gauge creeping higher than it did with the standard grill. If this is the case you can easily remove the grill again and refit the original.
• If you received instructions with your kit please refer to them as well as this tutorial. They may be more specific about the item you are fitting, while probably being less specific about the bike. By using both sources of information you should be able to solve any problems you encounter.
• Do not be tempted to rush ahead and do something you're not sure about. If you encounter any problems please re-read the instructions carefully and make sure you haven't missed anything. It is better to take twice as long and get it right, than to rush it and end up breaking something.
• The engine and surrounding areas can get very warm when the engine is running, and they will remain hot for some time after the engine is stopped. The exhaust in particular will get very hot, very quickly. Be careful not to burn yourself when working on your bike, or better yet, wait until the engine has cooled before starting any work.
• Follow these instructions at your own risk. While every effort has been made to ensure that this tutorial is safe and accurate, I can accept no responsibility for any damage you do to either yourself or your bike while following the instructions provided. If you are not sure about something, check the instructions again, and if you are still not sure then ask someone more experienced to help.

Instructions

First you must remove the original radiator cover which consists of three parts, namely the plastic grill and the two aluminium end plates.

The plastic grill is held on by two lugs on the top edge of the radiator, and two more on the bottom. There should be plenty of flexibility in the grill allowing you to unclip it. Simply lift the top edge of the grill over the lugs, one at a time, and when both are undone the whole grill can be lowered to release it from the lower lugs.

Next you must remove the end plates. Each of these is held on by two bolts which go into the side of the radiator (these bolts do not hold the coolant in, so removing them does not require the cooling system to be drained). Loosen and remove each bolt using the Allen key. Hold each end plate in place while you remove the last bolt so that it doesn't fall.

You should now be ready to fit the new grill. Most of these grills do not include new bolts, so you will probably need to reuse the original bolts.

Hold the new grill in position and put the upper bolt back in on one side. Do not tighten it yet. A few turns is all that is required. This will hold that side of the grill in place while allowing the other side to move, making it simple to line up the holes on the other side.

Next put the upper bolt back in place on the other side, and again do no tighten it yet. This will hold the grill securely while still allowing the lower edge to move so that you can easily line up the holes.

Next put the bolts back into the lower holes and then tighten all four bolts with your fingers.

The grill should now be in its final position but you will probably be able to move it slightly. If it doesn't quite look straight you can still adjust it until you are happy.

Once you are happy with the final position, hold it steady and tighten all four bolts with your Allen key.