Removing inner this week for painting, need tips!!
Extreme HDF Member
Joined: Apr 2006
Posts: 10,449
Likes: 46
From: Roswell, GA
Before you start, look over the parts you will be removing to be sure you have the tools necessary. For example, you will need snap ring pliers to remove the snap ring at the bottom of the clutch perch so you can remove the clutch cable. You will also need a couple of sizes of Torx bits for the outer fairing screws (T27) and others for the switch housings.
It's also a good time to lube the clutch and throttle cables.
It's also a good time to lube the clutch and throttle cables.
Road Warrior
Joined: Jan 2006
Posts: 1,823
Likes: 4
From: London, Canada
I just put my inner fairing back on and I have two tips I can share with you. 1. Take the radio out. It makes putting the new fairing on alot easier. I believe the old fairing would come off alot easier with the radio removed but since the service manual didn't mention it I left it in. After about 30 frustrating minutes trying to get the new fairing on without scratching it, I removed the radio and it went on much easier. The second tip and its important! 2. the bottom screw for the radio speaker is shorter than the other two. If you put the longer screw in the bottom hole it will poke a hole in your new fairing. unfortunately I learned this lesson the hard way. Its a small hole so I'm going to live with it untill winter and then replace it again.
Mark
Mark
Cruiser
Joined: Oct 2008
Posts: 214
Likes: 0
From: Mooresboro NC
mark
Road Warrior
Joined: Jan 2007
Posts: 1,296
Likes: 2
From: canada
+1 on the manual. However, it tells you to lock the forks before removing the ignition, but doesn't tell you to unlock them, so you have your ignition out, the forks locked, and can't get the inner out. Be sure to ignore that - just remember the position of the ignition switch when you remove it. Hell; even if you forget (like I did), it's easy enough with a long flathead & flashlight to get the ignition back in.
Cannon
Cannon
Road Captain
Joined: Jun 2008
Posts: 613
Likes: 2
From: Tallmadge, Ohio
I did a small write up when I did mine, taking pictures from the forum, the actual swap and the service manual. It might prove to be helpful and if used, I would love to know if it helped or what might be beneficial to add. You can see this on "HOW TO" section (right side of screen) at http://www.harleybill.com (just my personal website so nothing fancy).
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
