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How to Disassemble HD Fairing

Disassembling a Harley-Davidson fairing involves a few tools, your least favorite flannel shirt, a small square of thick cardboard and about two hours of your time. The fairing should be thought of as two parts--the outer fairing, which always faces your destination, and the inner fairing, which always faces you.

Instructions

1

Fold a flannel shirt over your front fender to preserve the paint and the chrome.

2

Remove seven screws with a Torx driver--the three screws just under the windshield on the outer fairing, and the two screws above each wind deflector on the left and right side of the inner fairing.

3

Turn the handlebar all the way left to access the fairing screw under the right fairing cap, and all the way right to access the fairing screw under the left fairing cap. Remove both screws with a Torx socket, socket extension and socket wrench.

4

Straddle the front fender and gently pull the outer fairing toward you. Squeeze together both sides of the clip on the back of the head light assembly with your fingers. Lift the fairing first, then the windshield off the front of the motorcycle.

5

Disconnect the turn signal and high-low beam connectors from the front wiring harness. Loosen and remove the passing lamp bracket from the fork brackets with a Torx socket, socket extension and socket wrench.

6

Put the key in the ignition, switch the key to "unlock" and rotate the ignition assembly knob to "access."

7

Release the ignition knob by depressing the ignition knob release tab with a flat-head screwdriver and turning the key counterclockwise. Pull the knob up and set aside.

8

Loosen then remove the switch nut hardware from the threaded switch nut stud with a socket wrench, socket extension and an open-end socket. Pull the chrome inner fairing trim from the inner fairing.

9

Unlock the clutch cable adjuster locknut from the clutch cable adjuster nut with two combination wrenches. Spin the clutch cable adjuster nut with your fingers until the clutch cable is completely slack.

10

Remove clutch hand-control pivot pin retaining ring on the bottom of the clutch hand-control bracket and the hand-control pivot pin with a flat-head screwdriver. Unbolt the clutch hand-control bracket from the left handlebar with a Torx socket, socket extension and socket wrench.

11

Unhook the clutch cable from the hand control and remove the anchor pin. Push the clutch cable through the clutch cable grommet from the inner fairing to the front of the motorcycle.

12

Stick a 1/8-inch-thick square of cardboard between the front-brake hand control and the front-brake hand-control bracket to protect the small, mechanical components of the brake-light relay inside the front brake hand-control bracket.

13

Remove the right handlebar switch housing and rear brake master cylinder with a Torx driver.

14

Pry the throttle from the end of the handlebar with a screwdriver and unhook the two throttle cables from the throttle. Push the throttle cables through the throttle cables grommet from the inner fairing to the front of the motorcycle.

15

Unplug the cigarette lighter quick-connect from the front wiring harness. Disconnect the speaker adapters on both sides of the inner fairing with a socket wrench, Torx socket and socket extension.

16

Disconnect the fuel gauge and voltmeter from the front wiring harness. Loosen and remove the four socket head screws that join the fairing bracket and the inner fairing with a Torx socket, socket extension and socket wrench.

17

Pry and lift both the inner fairing and the fairing bracket off the fairing bracket mounting pins. Pry the fairing bracket and inner fairing apart, and remove the inner fairing.

Posted by Unknown at 10:45 AM

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