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Sandy,

The job is pretty easy the second time, it's the first time that is hard.

Take a peak at the link that Red provided.

Though I am gonna tweak his list a bit.

1. Remove the ram air duct covers from the left and right sides. 1 screw in each to the rear and a pressure hole mount (just lift up) in the front.

2. Use a screwdriver to lift up the spring rings on the rubber ram air tube from the plastic ducts, one on each side. Don't take the spring ring off, just slide it up towards the front of the bike. With the screwdriver under the ring as a fulcrum, work your way around the ring with your fingers until the whole spring ring is out of the rubber holding channel. Once it's off the rubber tube and plastic duct line will slide right apart.

3. Remove the left and right lower fairing bolts (1 on each side) that are slightly behind where the ram air duct covers were.

4. Remove the left and right upper fairing bolts (1 on each side) on the sides of the instrument cluster. Be ready to catch washer as bolts are removed.

5. Remove both mirrors.

6. Remove 3 fairing screws on outside of fairing and 1 fairing screw on inside of fairing (near small hole) adjacent to where the front signal is. Repeat for each side. 8 screws total.

Here's where you need a helper.

7. ''Slightly'' lift fairing up off of bike.

8. Disconnect electrical lead wire, from the front of the bike from the fairing. This lead wire goes to the headlight and turn signal lights. There is only about 8 inches slack in this wire. Connect is tough to pull apart.

Almost done. (Here is where my instructions will differ from Reds)

9. Reach down right near the center of the triple arm and squeeze a pinch clamp on a rubber hose connecting a hose coming straight out of the frame to the plastic air duct lead that connects to the front fairing. Leave the pinch clamp on the rubber wire, only need to move it about 3/4 an inch. Slide the rubber hose off the plastic air duct lead.

10. Remove fairing from bike.

Now, on my bike (2002 California Model) it was not necessary to remove the single screw under the fairing nose, NOR remove the two screws under the front of the fairing (as if you were looking up from the forks) that connect through the bottom of the front fairing into the air intake ducts.

I did that when I removed mine, later I found out that you didn't need to. (My initial try I didn't do steps 2 and 9 above) It was a bitch to try and put the fairing back on with the air ducts connected to the bike. Finally I installed the ducts into the fairing first, then it was a lot easier to but the front fairing back on.

One screw on each front turn signals removes a mounting plate and then use a screw driver to remove the second mounting plate and rubber grommet. Cut the stock harness wire closer to the signal end (not the connector end) so you have plenty of slack to work with the wires on the new turn signals.



And here's a cut and paste from the other thread:

A few words of advice to others tackling the project.

1. Don't forget to plug your electric harness back in before you mount everything back on.

2. Set a chair or table or something in front of your bike, put the front fairing on that, plug it in, and TEST THE SIGNALS to make sure they work before you mount everything back on. If there is anything wrong with the wiring, you get a fast blink. Test both the left and right turn signals (front and rear) and test the hazards. NOTE: On both my front and rears the hot wire was a yellow wire with a stripe on it and the ground wire was solid green. On the short stalks they had all black wires, one with a stripe (hot) and one solid (ground) so that make it easy, the fronts hooked up the same way as the rears.

3. While all that stuff is off of there, not a bad time to do some cleaning, so I did.

4. REAL IMPORTANT Thread the adapters, washers and bolt and any heat shrink over the wire BEFORE you splice it into the existing stock wire. (Like Red mentioned, the stock wire connector is too big to run thru any holes) Also for the 02's that wire plug is behind the headlights, not down in the side of the fairing.

5. Might want to have a helper to get the fairing on and off so you don't drop/bump/scratch it.

6. To reattach, might want to start by threading the upper fairing back onto the mounting holes for the mirrors. Starting there, you know you got it lined up right.

7. Pay close attention to where the front fairing will connect to the engine fairing. There is an alignment tab, which goes in the back, not the front, so make sure you got that lined up as you thread stuff back on.

And to reattach the fairing basically follow a reverse order of the first set of instructions above. I'd say get everything (bolts and screws) just partially hand tightened to make sure everything is on and lined up properly before you go and do the final tightening down.


Good luck, any problems post and let us know, happy to help.

-Flash





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"We are what we repeatedly do. Excellence, then, is not an act, but habit" - Aristotle
 

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Thanks guys..ill print these instructions and hopefully tackle the job this week. I have been scared to mess with the bike, scared to mess it up, but came to the same conclusion i did with my first computer i ever had..if you dont try, youll never know..again thanks for the replies..Sandy

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Need help guys..i bought a set of flush mount turn signals for my 600 and cannot for the sake of me figure out how to take the factory lights off..I have tried unscrewing the screws out and messing with the rubber groumets but to no avail. There has got to be an easier way...HELP!!!!

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I mounted flush mounts signals that are slightly oversized that cover the holes perfectly. I did not have to remove any parts whatsoever. All I did was pull firmly on the stalk and cut the wires. (no tools... no kidding) I used some twisting & pressure to peel the stalk out. It's only rubber, held inside with a small metal plate and phillips screw. The flush mount base required a slight hand bending to follow the shape of the faring, drilled two mounting holes, securly with screws & rubber cement... I'm sure you can mount signals... anyway, give that a try without tearing the front end apart.

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NoFear
 

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The flush mounts i bought have double sided tape that mounts around the hole. I guess I could manhandle stalks but I just dont want to damage the fairing. If I could get them out that is all I need. I could pull the wire and mount. Thanks. Sandy

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Sandy,

YOu can always try and do it that way.

If you want to try, you can insert a screwdriver into the hole on the back underside of the fairing. This hole is right next to the screw adjacent to the back side of the turn signal. From that hole loosen the screw that holds the stock turn signal.

You'll need to use a magnetic screw driver to make sure the screw does not get lost down in the fairing.

Once that screw is loose you can pull the turn signal away from the bike and insert an awl or small screwdriver to pop the holding plate off.

From there pull the wire out as far as you can and make sure you got a hold of the two small metal plates and cut the wires and remove the turn signal. make sure you are holding the two plates, otherwise they will slip and fall into the inside of the fairing. Now, depending on how much slack you have in the wires, you can try installing the flush mount from there. I recommend heat shrink tubing, solder etc, to make sure the wiring stays.

Since you are not unplugging the electrical harness molex behind the windscreen, you'll need to remove both seats and disconnect the positive battery terminal.

Clean and dry the area that the flush mount will be sticking to as sometimes there is rubber residue from the stock mounting hole adapter.

Good luck.

-Flash

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"We are what we repeatedly do. Excellence, then, is not an act, but habit" - Aristotle
 

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Just a little off topic question... are flush mount signals legal or illegal? Can a bike be certified with these flush mount lights on??
 

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In my state, there legal, but you have to be able to see them from a specified distance. Break & blinkers 300 feet. Check your local motorcycle laws. Hope this helps[:p]
 

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where did you get his info mr.ed? you have a link?
 

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Arturo: Upon taking the MSF class, they give you a hard copy of the Texas motorcycle laws. If you haven't taken the class, it's well worth it. You learn some good survival skills plus exemption from the driving portion when getting your license. Anyway, here is a link

http://www.txdps.state.tx.us/msb
 
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