Front Fairing Frame Replacement

[Rootboy]

I am about to embark on this job....anyone here done it before that can offer advice would be appreciated. About five years ago, my brother dropped the bike after hitting some gravel. Luckily, nothing was damaged except the left valve cover (scratched) and the fairing frame. It has bothered me for years, because the faring has been "off" ever since. After all this time, I finally found a frame to make the repair. I've dug around the area on numerous occasions to add HIDs, new horn and Blinker Buddies, so I am comfortable jumping in. My initial concern is to make sure I have all the wiring harnesses/bundles routed correctly. I thought of photographing the entire mess as a reference...thoughts????

[CoffeeGuy]

I've actually done it twice in a six month period. Once to replace my bent frame with a slightly less bent one, then again to replace that with a good one.

Really nothing to it, I covered the front fender in cardboard, and went to work.

I think you'll find manuvering the new one on is the trickiest part. Just take some photos of the wiring- it's pretty obvious as they'll be kinks in most of it that show you where to route. A nice thing to do is to replace all your instrument bulbs while you have everything off. The first go through I had one go out a few days after disassembly and it really got my goat.

[CoffeeGuy]

I can post some pics this evening.
Basically you remove side panels, intake snorkel, fuel tank bolts (to create access by pulling tank back a bit), mirrors, windshield, headlight assembly, cluster (tie it up or rest it on top clamp), horn.

Remove bolts for each relay box, cut all zip ties (I found I needed much fewer than were on my bike), remove bolts for oil cooler and let it rest on cardboard on the fender.

Remove the three bolts for the subframe (two on each side, one at top). Wrestle it out, and carefully get the new frame in, noting position of relay boxes and oil lines.

Be careful to make sure all the threaded clips are present and positioned correctly on the new frame or you'll wonder why a fastener won't go in.

Pretty easy really. The hardest part is negotiating the new frame on. Just turn the forks as needed and "it's all good" as we kids say.

I'm at my shop putting new tires on, and if I err get home I'll post my pics if you'd like.

[CoffeeGuy]

Blame any typos on my iPhone.

[Rootboy]

Thanks for the advice CoffeeGuy. It has been so hot in Chicagoland, I may jump in to his project this weekend.... I am certainly not doing a whole lot of riding in this weather.

Sam