Introduction

A Hugger is basically just a big mudguard which is mounted very close to the rear wheel. In fact, I believe it gets it's name because it appears to "hug" the wheel.

It is a good idea to fit a hugger on a Hornet to protect the rear suspension from all the dirt and stones thrown up by the wheel. After fitting one you will notice that it is a lot easier to keep the area under the seat clean.

This tutorial shows you what is involved in fitting a hugger over the rear wheel of a 1999 model Honda CB600F Hornet. More recent models, or the CB900F Hornet, may be slightly different.

I am not sure what make of hugger mine is, although I suspect that it might be a Powerbronze. The photo shows what it looks like when fitted. There are other models available but as far as I know they all fit in a similar way, and they all require removal of the original chain guard.

Requirements

Warnings

• 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.
• When working near your chain be very careful not to get your fingers caught between the chain and sprocket. There have been cases where people have lost a finger by getting it trapped while the wheel was turning.
• 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

Before you start working on the bike you should make sure that that your hugger kit contains all the parts it should. If it is like mine these parts will include the plastic shell of the hugger, four rubber grommets, four metal sleeves, a metal bracket, two nuts and four bolts. If everything is included you are ready to start fitting it.

Start by preparing your hugger for fitting. You should see four small bolt holes drilled in it, one at either end of the chain guard and two (closer together) on the other side. Put one of the rubber grommets into each of these holes, making sure they are seated properly on both sides of the plastic.

Next you should attach the bracket to the hugger because it is a lot easier to do now without the wheel in the way. Place one of the metal sleeves through each of the two grommets on the side which will be away from the chain. Then bolt the bracket to the inside of the hugger using two of the bolts and the two nuts. Do not fully tighten the bolts yet. If they are just hand tight you will still be able to move the bracket, making it easier to align it with the mounting points on the bike.

Now you will need to remove the bike's original chain guard. This is held on by two bolts which screw into lugs welded to the top of the swingarm. Unfortunately one of the bolts is hidden behind the footrest hanger, so you will need to remove this first. Undo the two bolts highlighted in the picture and lower the footrest hanger to the floor. It will still be attached by the gear shift linkage but this will not stop you setting it on the ground. If you undo the lower bolt first the hanger will remain steady while you undo the upper one. Once the footrest is out of the way you can undo the two bolts holding the chain guard in place and lift it off the swingarm.

The lower end of the hugger bracket will be held onto the swingarm by the two bolts which are currently holding the brake hose in place. Undo each of these bolts and set them in a safe place. You will need them again shortly.

You are now ready to start fixing the hugger to the bike. Manoeuvre it into position over the wheel. It will probably be easier if you work from the left side of the bike (from the rider's point of view) and bring the hugger over the chain, mainly because the biggest part of the hugger will remain on this side, but also because you will have more clearance after removing the footrest hanger. Check that the lower part of the metal bracket goes below the brake hose.

When you are happy with the position you can start putting the bolts in place. Do not tighten any of the bolts until they are all in place.

Reuse the original bolts to hold the brake hose clips and the hugger bracket to the swingarm, making sure the hose runs along the top of the bracket as shown in the picture. I have braided hoses fitted in the picture and the clips have been changed because of this. If you still have the bike's original brake hoses your clips will be bigger, but they will still fit over the bracket.

Put the remaining metal sleeves through the rubber grommets on the chain guard side of the hugger and bolt these to the lugs which held the original chain guard. The lugs are threaded so you should not need any nuts to hold these bolts in place.

When all the bolts are in place, check that the hugger is not rubbing on the wheel or interfering with the exhaust, and if all is well you can tighten all the bolts. It can be awkward to get at the two nuts securing the hugger to the bracket, but there should be enough space to slip a spanner between the wheel and the hugger. Failing that, you might be able to reach them with your fingers and apply enough pressure to stop them moving while you tighten the bolts. Also do not over tighten the bolts on the chain guard. They need to be tight enough to ensure they will not come loose, but I have heard that too much pressure while tightening them can snap the lugs off the top of the swingarm.

All that remains now is to refit the footrest hanger. Be careful not to twist it around the gear shift linkage, or your gear shift lever will end up in a slightly different position than before. Lift the footrest hanger carefully back into position and put the upper bolt back in first. This will hold it steady while you put the lower bolt back in. When both bolts are back in place, tighten them both. If you have a torque wrench the correct torque setting for these bolts is 26Nm (about 19 lb/ft). If not, just make sure they are tight.

Congratulations. You should now have successfully fitted your hugger. The only thing left to do is to take the bike for a test ride, safe in the knowledge that your rear suspension is protected from any dirt and stones thrown up by the wheel. While riding the bike listen for any noises coming from the back of the bike, particularly when travelling over bumpy roads. If you hear anything unusual the hugger could be shaking around and touching the wheel or bodywork, and you might need to adjust its position and make sure that it is tightened up properly.