Bodywork components
Contents
Rear mudguard - removal and installation 5
Body panels - and installation 3
Rear view mirrors - removal and installation 2
Front mudguard - removal and installation 4
Seat - removal and 6
General information 1
Passenger grab-rail - removal and installation 7
of
Easy, suitable for easy, suitable Fairly suitable for Very
novice with little for beginner with suitable for competent experienced DIY suitable for expert DIY
experience some experience mechanic mechanic or professional
Where a panel engages another by means of
1 General information tabs, be not to break the tab or its 2 Rear view mirrors -
mating slot or to damage the paintwork. removal and installation
Remember that a few moments of patience at
this stage will save you a lot of money in
replacing broken fairing panels!
This Chapter covers the procedures
Removal
When installing a body panel, first study it
necessary to remove and install the body
noting any fasteners and associated
1 Unscrew the mirror from its mounting on
parts. Since many service and repair
fittings removed with it, to be sure of returning
the handlebar, using a suitable spanner on the
operations on these motorcycles require the
everything to its correct place. Check that all
lower nut to initially slacken it (see
removal of the body parts, the procedures are
fasteners are in good condition, including all illustration).
grouped here and referred to from other
trim nuts or clips and damping/rubber mounts;
Chapters.
Installation
any of these must be replaced if faulty before
In the case of damage to the body parts, it
the panel is reassembled. Check also that all 2 Install the mirror into its mounting and
is usually necessary to remove the broken
mounting brackets are straight and repair or screw it in until it is fully home. If the position
component and replace it with a new (or used)
replace them if necessary before attempting to of the mirror is not as required, counter-hold
one. The material that the body panels are
install the panel. Where assistance was the lower nut on the stem and slacken the top
composed of doesn't lend itself to
nut. Adjust the mirror as required, then tighten
required to remove a panel, make sure your
conventional repair techniques. There are
the top nut whilst counter-holding the mirror.
assistant is on hand to install it.
however some shops that specialise in
"plastic welding", so it may be worthwhile Carefully settle the panel in place,
seeking the advice of one of these specialists the instructions provided, and check that it
before consigning an expensive component engages correctly with its partners (where
to the bin. applicable) before tightening any of the
When attempting to remove any body panel, fasteners. Where a panel engages another by
first study it closely, noting any fasteners and means of tabs, be careful not to break the tab
associated fittings, to be sure of returning or its mating slot. Note that a small amount of
everything to its correct place on installation. lubricant (liquid soap or similar) applied to the
In some cases the aid of an assistant will be mounting rubbers of the side panels will assist
required when removing panels, to help avoid the panel retaining pegs to engage without
the risk of damage to paintwork. Once the the need for undue pressure.
evident fasteners have been removed, try to Tighten the fasteners securely, but be
withdraw the panel as described but DO NOT
careful not to any of them or the
FORCE IT - if it will not release, check that all
panel may break (not always immediately) due
2.1 Mirror mounting nut (A) and locknut (B)
fasteners have been removed and try again. to the uneven stress.
 Bodywork components
3.2a Side panel mounting points (arrows) 3.2b Release the panel from its pegs 3.2c draw it forward to release the
3.5a The rear cowl is secured by a bolt on
3,5b and two at the rear (arrows)
each side
A smear of liquid soap
3 Body panels -
4 Front mudguard -
(washing-up liquid is ideal)
removal and installation
removal and installation
applied to the mounting
grommets will help the side
panel pegs engage without the need for
undue pressure.
Removal
Side panels
1 Remove the front wheel (see Chapter 7).
Removal
2 Remove the screws securing the sides of
Rear cowl
1 Remove the seat (see Section 6).
the mudguard to the forks, noting the position
2 The side panels are secured by two pegs at
Removal of the brake hose clamp (see illustration).
the front which fit into rubber grommets, and
Withdraw the speedometer cable from its
4 Remove the side panels (see above).
a tab at the rear which locates into the front of
guide on the mudguard.
5 Unscrew the two side bolts and the two
the rear cowl (see illustration). Gently pull the
3 Carefully remove the mudguard by sliding it
rear bolts the rear cowl to the frame,
panel away from the frame to release the
downwards until it clears the bottom of the
then carefully draw the cowl backwards until it
pegs, then draw it forwards to release the tab forks.
is clear of the passenger grab-rail, noting how
from the rear cowl (see illustrations). Do not
Installation
it fits (see illustrations).
force or bend the panel while removing it.
4 Installation is the reverse of removal. Make
sure the brake hose and speedometer cable
Installation
Installation
are correctly routed and secured by their
3 Installation is the reverse of removal.
6 Installation is the reverse of removal.
clamps (see illustrations).
4.2 Front mudguard mounting bolts
4.4a Note the fitting of the brake hose
4.4b Pass the speedometer cable
clamp (arrow)
through its guide
Bodywork components
The seat lock is below the tail light 6.2 Note the tab (A), the side hooks (B), and the lock latch (C)
which secure the seat
fluid reservoir (see Chapter 7), and the ignition tank mounting bracket, and how the seat
5 Rear mudguard -
control unit (see Chapter 5). locates onto the frame rail (see illustration).
removal and installation 3 Remove all clips and bolts securing the rear
Installation
mudguard sections and remove them from
3 Locate the tab at the front of the seat under
the frame.
the fuel tank mounting bracket. Align the seat
Removal Installation
at the rear and push down on it to engage the
latches (see illustration).
1 The rear mudguard comes in two sections. 4 Installation is the reverse of removal.
The front section is mounted to the frame rails
under the seat and incorporates the battery
7 grab-rail -
6 Seat - removal and installation
case. The rear section is mounted to the end
removal and installation
of the frame and incorporates the rear tail light
assembly and the rear turn signal assemblies,
and has the licence plate mounted to it.
2 Remove the seat (see Section 6), the
Removal
Removal
battery (see Chapter 9), the rear cowl (see
1 Remove the seat (see Section 6).
1 Insert the ignition key into the seat lock
Section 3), the passenger grab-rail (see
2 Remove the rear cowl (see Section 3).
Section 7), the tail light assembly (see Chapter which is located below the tail light assembly
3 Unscrew the four bolts securing the grab-
9) and the rear turn signal assemblies (see and turn it clockwise to unlock the seat (see
rail to the frame and remove the grab-rail (see
Chapter 9). Also move aside all ancillary illustration).
illustration).
components such as the fuel pump and the 2 Lift the rear of the seat and draw it back
Installation
various electrical components attached to the
and away from the bike. Note how the tab at
rear mudguard (see Chapter 9), the rear brake
the front of the seat locates under the fuel
4 Installation is the reverse of removal.
8
6.3 Locate the tab (A) under the fuel tank bracket (B)
7.3 The grab-rail is secured by a bolt on each side at the front (A),
and at the back (B)