Removing inner this week for painting, need tips!!
Thread Starter
|
Road Master
Joined: Apr 2008
Posts: 1,034
Likes: 1
Removing inner this week for painting, need tips!!
I am removing my inner this week to be painted this weekend and I heard it is a PITA to do so. I know I posted this before and lost it like a D/A!! I think the most dificult part will be the ignition. I know to label and mark ALL electrical connections and write them down as such when done so. Any inside tips would be greatly appreciated!!
Road Master
Joined: Apr 2008
Posts: 752
Likes: 0
From: North East, Florida
Time consuming, yes. PITA, not really. When I did mine, I laid a blanket on he garage floor and put the parts on it in order, top to bottom so it was easy to know which part went on next during assembly. The shop manual is pretty detailed on removing the ignition switch. I tagged all my wires but all the electrical connectors are a different size so you can't get them mixed up.
Extreme HDF Member
Joined: Apr 2006
Posts: 10,449
Likes: 46
From: Roswell, GA
Use the HD Service Manual; it has an excellent step by step description. The job is tedious (because of all the gauges, connectors, etc.) but not a PITA, unless you don't have SM.
If your bike is pre-'09, buy a couple of brass ferrules that secure the cables in the hand grip. These are easily lost and a pita to find after they fall. Having the extra on hand is cheap job interruption insurance and you can always return what you don't use.
Good luck with your project.
If your bike is pre-'09, buy a couple of brass ferrules that secure the cables in the hand grip. These are easily lost and a pita to find after they fall. Having the extra on hand is cheap job interruption insurance and you can always return what you don't use.
Good luck with your project.
Last edited by Harleypingman; Apr 19, 2009 at 09:25 PM.
Cruiser
Joined: Oct 2008
Posts: 214
Likes: 0
From: Mooresboro NC
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
Outstanding HDF Member
Joined: Mar 2009
Posts: 2,930
Likes: 4
From: OHIO......UGH !!
+1 on the blanket !! I laid everything out , IN ORDER, as I took it off !!
Buy the wire labeling kit at Home Depot, and label EVERYTHING !!
I took a cardboard box lid, and marked all of the nuts & bolts & little parts I took off !!
Take A LOT of pictures !! As soon as you get the batwing off, take CLOSE UP pictures of EVERYTHING !! I took pictures of each guage, cable, adjustment, etc.......
I took pictures of how all of the wires were routed under the batwing.
Read the threads on the brake light switch located in the switch cap. Once you understand how it works, you will install a THICK spacer in the front brake handle, so that you too don't have to pay the dealer $ 63 for a new one !!
Read this thread when re-installing ignition switch. It will save you 1 headache & 1 hour of your time !!
https://www.hdforums.com/forum/touri...back-help.html
Take your time !!! Use the factory manual !!
Here is the thread I posted after finishing mine !!
https://www.hdforums.com/forum/touri...-you-guys.html
Once it's all done, you'll be glad that YOU did it !!
We'll be expecting pics when you're done !!
Buy the wire labeling kit at Home Depot, and label EVERYTHING !!
I took a cardboard box lid, and marked all of the nuts & bolts & little parts I took off !!
Take A LOT of pictures !! As soon as you get the batwing off, take CLOSE UP pictures of EVERYTHING !! I took pictures of each guage, cable, adjustment, etc.......
I took pictures of how all of the wires were routed under the batwing.
Read the threads on the brake light switch located in the switch cap. Once you understand how it works, you will install a THICK spacer in the front brake handle, so that you too don't have to pay the dealer $ 63 for a new one !!
Read this thread when re-installing ignition switch. It will save you 1 headache & 1 hour of your time !!
https://www.hdforums.com/forum/touri...back-help.html
Take your time !!! Use the factory manual !!
Here is the thread I posted after finishing mine !!
https://www.hdforums.com/forum/touri...-you-guys.html
Once it's all done, you'll be glad that YOU did it !!
We'll be expecting pics when you're done !!
Trending Topics
Extreme HDF Member
Joined: May 2005
Posts: 16,656
Likes: 13
From: The Big Easy
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
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Road Warrior
Joined: Nov 2006
Posts: 1,738
Likes: 7
From: St. Charles, IL
Another vote for buying the service manual. Why people try to work on a vehicle without a service manual is beyond me.
A few other tips;
Take lots of pictures
Label all wires on both sides of the connections, stay simple like A:A, B:B
Zip tie wire bundles where they sit, once plugs are undone, cable bundles will sag out of place and can be hard to get them back into OEM positions
A few other tips;
Take lots of pictures
Label all wires on both sides of the connections, stay simple like A:A, B:B
Zip tie wire bundles where they sit, once plugs are undone, cable bundles will sag out of place and can be hard to get them back into OEM positions
