Inner fairing removal/replacement? (HELP!!!)
 

So anyone out there done this? Got my inner back from painter.
http://www.doofclenas.com/forums/att...1&d=1210610860
http://www.doofclenas.com/forums/att...1&d=1210610860
and am hesitant to do the job myself. Looks like it shouldn't be to tough, but scared of marring the new paint on it trying. Dealer wants $192 to install it. Should I do it or pay up for them to do it? Yes Rock I know your answer, let the dealer do it right the first time. Any other opinions?

No idea on what to tell you other than it looks fantastic.

Go slow and do it yourself. No one will take care of your bike better than you.


Looks good by the way.

Its not hard, just take your time and go slow, dont force nothing. I have had mine off several times and it is just time consuming, but I enjoy working on my bike as a form of bad weather recreation.

Did you take it off?

nah, started then decided to run to town pick up new seals for edges and bottom of fairing, new clutch and throttle cable grommets, handlebar grommets. When I pulled off outer I looked for the first time I guess, and noticed left fairing support broken and right side showing signs of fatigue so picked up both of those. Chrome bezels for gages and radio. $130 and I'm back home... now to go take lots of pics of that maze of wires, and use a paint pen to mark some plugs just for my peace of mind.

OK, how do I unlock the forks after pulling the ign. switch out? do I have to have the HD tool? remember a thread here said use a screwdriver and there are two places it should engage, I can only seem to find one and it doesn't unlock the forks or turn on the ignition.



not seeming like a good start here.

Good plan. I do the same thing!

no idea.... but someone will...

ok done got past that! whew! got it back in several times but would not unlock or no ignition worky. finally got it all back in sync, and THEN discovered you dont have to put it in fork lock position manual calls for, simply leave it at "off" insert key, turn key backwards a bit, use finger to derpress little tab below knob and pull straight up... much easer than what HD says in the manual geesh

jebus crispy what a pain in the arse. its off, now back off to town to get a couple of spare brass throttle cable ferruls and some cable lube. Been needing to lube the cables a long time anyway, should have thought of that when I was in town earlier. Looks like this is going to be put back together tomorrow not today :D

the pics of the process are humbling man...

at least you are getting a lot of quality help here...

took before pics with the outer off, didn't take many along the way, now its just a big ole pile of wires now :D

While I was at the dealer decided to get a set of pullback bars as well. They said it would work with stock cables etc but not recommended on clutch, but it's going to have to till I get some more monies for braded cables and brake lines.

pulled in the driveway a bit ago with the headlights shining on the bike and just stared at it for a bit with no fairing.
made me wish my ignition wasn't on the fairing, if not for that it probably wouldn't be a big deal to put a Road King headlight nacelle on it. Think all the wires could probably be persuaded to fit in there maybe. To bad, looked kind of nice with the pullback bars and no fairing in the way, sort of looked like mini apes on RK. sigh...

enough of that crap, now gotta get back to what I gotta do to finish this job up! dang 2" gauges aren't tight in the new fairing for some reason, seems the old fairing must be slightly thicker there. swapped them back and forth a couple of times and each time they are tight in the old fairing but rattle in the new one gggrrrrrr.... going to have to go get some orings for gasket/spacers to go between fairing and gauge. They should be there anyway, tack and speedo have nice big rubber gaskets but small gauges have none... they will now.
other than that I don't foresee any hurdle to large to getting this thing back together other than figuring out that mess of wires hanging there, that shouldn't be to bad since I numbered all the connectors with a paint pen, simple as plugging #1 into #1 and on and on...hardest part may be trying to remember which direction they ran to make them reach.

This thread might help ya out.........
http://www.doofclenas.com/forums/sho...44&postcount=1

actually that thread makes me feel sick seeing how clean his bike was under his fairing.

mine not so much:
http://www.doofclenas.com/forums/att...1&d=1210649205

but I'm absoposotivley giddy with how its going to look when I can get done.

http://www.doofclenas.com/forums/att...1&d=1210649296
http://www.doofclenas.com/forums/att...1&d=1210649296

may not sleep much tonight