Related to cowling removal;

Blue Laser · Jul 18, 2006

Okay, I don't know what's goin' on here.

This is startin' to git EAR-uh-tate-in.

I got the screws/fasteners undone/removed, but now I can't

get anything past the nose. SOMEwhere in there is a screw or

two that need to come out but I can't find them.

On top of that, I can't find my dang 3/8" ratchet.

:help:

Jim

pawtracks · Jul 18, 2006

Can't help you with the 3/8" ratchet

What Rogue said in your other post made more sense to me (take it all out as one unit)

I know getting to those screws between the headlights was a pain.

Sorry, I can't think of anything else holding it in besides those screws

Once the windshield, cover and windshield bracket were off, the nose of the bike was clipped over the top of the instrument cluster.

I'm not sure of the angle of the instrument cluster screws you are after.

Maybe the headlights will have to come out anyway.

Rogue's idea still sounds best, of course I'm at my desk at work, not sweating out in the garage.

Sorry I can't be more help

Rogue · Jul 18, 2006

Remember there is a screw right in the center of the nose behind the gauges.

#41 in the parts drawing? Its one of the two I listed right under my pictures.

Blue Laser · Jul 18, 2006

Rogue,

Part #41 is the screw that goes to the small panel on top

of the nose cowling (starting to sound like airplane talk).

THAT screw is already off.

I'll take another look and get back to ya.

Jim

Rogue · Jul 18, 2006

Blue Laser said:
Rogue,
Part #41 is the screw that goes to the small panel on top

of the nose cowling (starting to sound like airplane talk).

THAT screw is already off.

I'll take another look and get back to ya.

Jim

Well the one that really got me the first time was that one right in the center behind the gauges.

I have no idea how to get to it without pulling the headlights too.

Blue Laser · Jul 18, 2006

Well the one that really got me the first time was that one right in the center behind the gauges.I have no idea how to get to it without pulling the headlights too.

I think I see the one you're talking about. There appears to be a big honkin'

relay just behind and below the gauges. In back (or in front, depending on your perspective)

of the relay is a pretty hefty phillips screw that I don't know how else to get to.

Looks like I'll be pullin' some more hex bolts off...ya do what ya can and what ya need to

ta get the job done.

I have no idea how else you'd get to that screw without droppin' it somewhere and never

finding it again. (Lost forever in the bowels of the lower tupperware).

Thanks for all the help, Rogue. Have a cold one on me.

Jim

Rogue · Jul 18, 2006

Blue Laser said:
Well the one that really got me the first time was that one right in the center behind the gauges.I have no idea how to get to it without pulling the headlights too.

Click to expand...

I think I see the one you're talking about. There appears to be a big honkin'

relay just behind and below the gauges. In back (or in front, depending on your perspective)

of the relay is a pretty hefty phillips screw that I don't know how else to get to.

Looks like I'll be pullin' some more hex bolts off...ya do what ya can and what ya need to

ta get the job done.

I have no idea how else you'd get to that screw without droppin' it somewhere and never

finding it again. (Lost forever in the bowels of the lower tupperware).

Thanks for all the help, Rogue. Have a cold one on me.

Jim

Yea,

That one sucks!

IIRC WC said somewhere that he never bothered to put it back in.

PerfectBlueride · Jul 19, 2006

When I first attempted to do some farkles after picking up my bike last March, I did it the hard way!

When I failed miserably trying to add some knock off blasters, I put it back together! Afterwards I had parts left over. :angry2:

So I took it back apart. When putting it back together I discovered if I connected the upper fairings and nose section I could get it back together with all screws and fasteners used.

I have been doing it that way for over a year now!, you just have to remember to remove the glove box solenoid! And make sure you do not knock off the mirror fasteners once you push the nose into place on the dash.

It is the easiest way to remove and reinstall the fairings!

Blue Laser · Jul 20, 2006

So I took it back apart. When putting it back together I discovered if I connected the upper fairings and nose section I could get it back together with all screws and fasteners used.

Got any pics?

I have been doing it that way for over a year now!, you just have to remember to remove the glove box solenoid!

Is that the connector underneath the glovebox (that actually looks kinda like a relay)

or is it the white connector like thingy that has a couple of wires running out from the

side of it?

As I've stated before, I'm not a wrench, but I'm not afraid to learn, either.

I'm getting ready to put the bike back together and take it to a dealer. This

is getting ridiculous. I didn't think it'd be this hard.

Jim

PerfectBlueride · Jul 24, 2006

Sorry I do not have any real usable pictures and sorry I have not replies to your inquiry sooner.

basically the glove box electrical connection holds the unlocking mechinum in place, that has to be removed in roder to pull the nose along with the upper fairings.

So if I were doing it from memory, remove windshield, 7 black plastic screws. maybe a steel one in the center botom.

wrap in a towel, place somewhere safe.

remove center motor panel under windshield. disconnect movement arms from guides.

go under nose remove two screws the hold it to the black plastic protection panels.

remove the 4 plastic black panels around fork area, remember there are screws/ fasteners on the inner sides were battery are and glove box pull those panels off.

remove mirrows, remove headlight screws there are 4.

remove the fasteners that connect the upper and lower fairings.

once you have done that lift up on the nose section that snaps over the dash, carefuuly pull the whole thing up and away. the glove box side is the hardest to clear, two people would be great, however I have done it by myself.

Be careful not to lose the mirror mount fasteners that hold the miiros in place they try to pop off/out when you pull the nose up off the dash.

before starting take a picture of things as you go.

when you put it back together the glove box once again is the most difficult because there are fasteners that connect it to the lower fairing, you'll find them when you try to remove the whole section and it does not want to release.

I am sure someone has a picture to offer up by now.

Tinker · Jul 24, 2006

I'm not clear about the rear of your bike. Mine is an '03. I remove, first the windshield and frame then pannels A,B,C and D. With those out there are five (5) recessed hex machine screws and four phillips sheet metal/plastic screws to remove as well as disconnecting the head lamp harness at the lamps. There are also four of the plastic pop fastners under thevery front of the center cowling. Dont forget to remove the battery and box, one of the fasteners is difficult to remove and impossible to install with it in place. The four large phillips screws hold the head lamp assembly in the sub-frame. With all fof those out the headlignt assem with the center front cowling will pull straigh foreward, mind the lip at the top of the instriment pannel. With the arm load of plastic firmly in hand you will see the large phillips which connects the two major components. Double jointed wrixtx and fingers are a distinct advantage.

Blue Laser · Jul 25, 2006

Hi, guys,

Just a quick note to all the folks that responded to my pleas for help

on getting the nose off.

Finally got it done, and dash indicator bulbs replaced on both sides.

Quite an ej-u-muh-kay-shun, I must say.

Again, many thanks, and if you need a hand with this sometime in the

future, please let me know.

Thanks to one and all...

Jim :yahoo: :yahoo: :yahoo:

pawtracks · Jul 25, 2006

Congrats! :clapping:

How did you do it?

Nasty center screw or headlights off as one unit?

Waaane · Jul 25, 2006

I have followed all of this with great interest as I kind of enjoy working on my bike...I posted nothing because I had nothing constructive to add...I just have to say that if these bulbs ever go out after my YES is gone I am sending my bike straight to the Blue Laser. I think he got a hell of an education...one I don't want...Where was he located again?

Good job all, I am glad the bike is back together

Rogue · Jul 26, 2006

Blue Laser said:
Hi, guys,
Just a quick note to all the folks that responded to my pleas for help

on getting the nose off.

Finally got it done, and dash indicator bulbs replaced on both sides.

Quite an ej-u-muh-kay-shun, I must say.

Again, many thanks, and if you need a hand with this sometime in the

future, please let me know.

Thanks to one and all...

Jim :yahoo: :yahoo: :yahoo:

:yahoo: :yahoo: :yahoo: :yahoo:

Blue Laser · Jul 26, 2006

pawtracks said:
Congrats! :clapping:
How did you do it?

Nasty center screw or headlights off as one unit?

Pawtracks,

Here is the sequence (as I remember it):

1. Windshield Frame (the blue one outside)

2. Windshield

3. Windshield Frame (the black one on the bottom)

4. Windshield Motor arm screws (Don't lose the two white spacers-one (1) per side)

5. Cover (Small squarish piece in the middle of the front fairing)

6. Left and Right mirrors (don't lose the rubber mirror "stops"...you'll know what I

mean when you see them the mirrors mount to these rubber pieces.

7. All four (4) Dash panels

8. Inner fairing panels (don't forget the fasteners)

9. Four large phillips screws-two (2) in front of the forks, and two slightly higher up

and a little bit outboard from the others. I think you'll see them as they're pretty

big screws considering the way the rest of the body work is put together.

10. I put a towel on the front fender

11. I pulled the nose out at this point (headlights still attached to the nose, but I did

disconnect the headlights. I left the glove box electrics attached as well.)

12. Unscrewed the "meter" panel with the three screws.

13. Disconnected the "meter" electronics connector (big honker at the top behind the speedo;

was a little tricky, as I had to wiggle it a little bit to get it out.)

14. Took off what I counted to be seven (7) screws on the rear of the meter panel to access

the bulbs.

15. Rotate connector to pull out of panel, and replace bulb(s).

16. Reverse order to put it back together.

I'm pretty sure that was everything, including little notes to help you avoid the pitfalls

and frustrations I experienced.

I hope this helps someone out there, but remember that I have an 2005 w/ABS.

Jim

Waaane said:
I have followed all of this with great interest as I kind of enjoy working on my bike...I posted nothing because I had nothing constructive to add...I just have to say that if these bulbs ever go out after my YES is gone I am sending my bike straight to the Blue Laser. I think he got a hell of an education...one I don't want...Where was he located again? Good job all, I am glad the bike is back together

Waaane,

I'm in Northern CA.

Jim

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