Fairing removal - 1990 kawasaki ZZR 1100

Loosen three screws and remove windshield from between fairing halves.

On the inner fairing just outside of the speakers there are two screws - remove them.

Turn the steering as required and remove two screws under the fairing cap.

Remove the three windshield screws you loosened before.

Lean the outer fairing forward and undo the headlight connector and then lift the outer fairing from the bike.

1993/1994 Outer Fairing and Windshield for FLHTC, and FLHTC ULTRA

Removal

First remove the headlight assembly and the bolts, nut and the washers attaching the outer fairing piece to the windshield and inner fairing piece. THEN loosen the four bolts attaching the light bracket and the outer fairing piece to the fork brackets. Remove the upper bolts but leave the lower ones in place. Cover the fender. THEN rest the lower light bracket onto the fender. THEN remove the fastener securing the headlamp trim ring and remove the trim ring. THEN remove five screws that secure then headlamp assembly to the outer fairing and remove the headlamp assembly. THEN reach through the headlamp opening and loosen four locknuts on the two studs on each side of the headlight area which attach the fairing to the metal brackets inside the fairing. THEN remove the fairing by pulling it straight ahead away from the brackets.

Installation

First loosely position the outer fairing in place over the inner faring with the four studs going into the two brackets. Then install the five windshield fasteners through the outer fairing, the windshield and the inner fairing. THEN tighten the four stud nuts to secure the fairing to the brackets, being sure to have the inner and the outer fairing properly aligned at their outside edges. THEN position the light bracket so that the slots fit around the upper fork bracket bolts and thenalign the lower fork bracket mounting holes and replace the two lowering fairing mounting bolts through the light bracket and the outer fairing and the inner fairing and screw them into the lower fork bracket. THEN make sure that the rubber seal around the inner fairing is properly seated and not pinched and tighten the four fairing attachment bolts to 12-13 foot pounds (16 -19 Nm). THEN tighten the windshield screws to 4 inch pounds (0.45 Nm) but no more than this amount starting in the middle and working outwards on both sides. THEN reinstall the headlight assembly.

I don't know if this will help. It was sent to me by a friend of mine and I've never tried the procedure. I do not work on these ignition switches and fork locks. This is for a newer model but it may help. Good Luck. Steve

Here's the procedure to remove the IGNITION /LIGHT KEY SWITCH AND FORK LOCK for a 2005 FLHT/C/U or FLTR (Domestic): Tools needed for removing ignition switch A T27 Torx, a small flat blade screwdriver, 7/8 wrench.

1. Remove the outer fairing and windshield

2. To remove the ignition switch, insert the ignition switch key and turn to the UNLOCK position. Leaving the key installed, rotate the knob to ACCESS. Depressing the release button at bottom (left side) with a small screwdriver, push key down and turn an additional 60 degrees in a counter-clockwise direction. Lift and remove knob.

3. Using a 7/8 wrench on flats, loosen switch nut and remove from threaded post of ignition switch housing. Remove collar and spacer.

4. Using a T27 TORX drive head, remove the two screws (with flat washers) that secure fairing cap to left and right sides of fairing.

5. Remove the switch position plate by pulling tabs from slots in faring cap. If necessary, raise the fairing cap slightly to facilitate removal.

6. With the forks turned fully to the left, disconnect the Fairing cap switch connector (105) 12-place Multilock (black), from behind right side of fairing cap. Depress the button on the plus side of the connector to pull apart the pin and socket halves.

7. Remove the fairing cap from the motorcycle.

8. Locate the ignition switch connector (33), 4-place Packard, at bottom of radio. Slide connector off anchor and separate pin and socket halves.
9. Remove the socket screws (with flat washers) and lift the switch housing from the upper fork bracket bore. Route the ignition switch connector to rear of inner fairing and remove switch housing from the vehicle.

Here is something a friend sent to me. I've never taken one of these switches out so I can't say for sure if this is correct but it's all I have.

Here's the procedure to remove the IGNITION /LIGHT KEY SWITCH AND FORK LOCK for a 2005 FLHT/C/U or FLTR (Domestic): Tools needed for removing ignition switch A T27 Torx, a small flat blade screwdriver, 7/8 wrench.

1. Remove the outer fairing and windshield

2. To remove the ignition switch, insert the ignition switch key and turn to the UNLOCK position. Leaving the key installed, rotate the knob to ACCESS. Depressing the release button at bottom (left side) with a small screwdriver, push key down and turn an additional 60 degrees in a counter-clockwise direction. Lift and remove knob.

3. Using a 7/8 wrench on flats, loosen switch nut and remove from threaded post of ignition switch housing. Remove collar and spacer.

4. Using a T27 TORX drive head, remove the two screws (with flat washers) that secure fairing cap to left and right sides of fairing.

5. Remove the switch position plate by pulling tabs from slots in faring cap. If necessary, raise the fairing cap slightly to facilitate removal.

6. With the forks turned fully to the left, disconnect the Fairing cap switch connector (105) 12-place Multilock (black), from behind right side of fairing cap. Depress the button on the plus side of the connector to pull apart the pin and socket halves.

7. Remove the fairing cap from the motorcycle.

8. Locate the ignition switch connector (33), 4-place Packard, at bottom of radio. Slide connector off anchor and separate pin and socket halves.

9. Remove the socket screws (with flat washers) and lift the switch housing from the upper fork bracket bore. Route the ignition switch connector to rear of inner fairing and remove switch housing from the vehicle.

HANDLEBAR REMOVAL

1. Remove maxi-fuse.

REMOVAL

1. Remove left side saddlebag.

2. Gently pull side cover from frame downtubes (no tools

required).

3. Depress latches on maxi-fuse holder and then slide

cover rearward to disengage tongue from groove in fuse

block cover.

4. Pull maxi-fuse from maxi-fuse holder.

2. Place blanket or protective cover over front of fuel tank to

protect against scratches or other damage.

FLHR/C/S:

Remove the handlebar clamp

(FLHR/C/S), NACELLE REMOVAL (FLHR/C), steps 1-

11, or NACELLE REMOVAL (FLHRS), steps 1-7.

WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S) 2.31

WINDSHIELD REMOVAL
Standing at the front of the motorcycle,

use a finger to raise the wireform latch springs on

both sides of the windshield.

2. Gently pull on the top of the windshield until the upper

notches on the windshield brackets are free of the upper

grommets.

3. Carefully raise the windshield until the lower notches are

free of the lower grommets.

4. Remove windshield from motorcycle.

WINDSHIELD INSTALLATIONTo avoid scratching headlamp nacelle or auxiliary lamp

bracket, be sure that all four notches on the windshield

brackets are firmly seated on a rubber grommet.

1. Standing at the front of the motorcycle, carefully insert

the windshield brackets between the headlamp nacelle

and the auxiliary lamp bracket. Lower the windshield into

position until the lower notches on the windshield brackets

are seated on the lower grommets.

2. Gently push the top of the windshield toward the rear

until the upper notches fully engage the upper grommets.

3. Push down on the wireform latch springs, so that they

overhang the rubber grommets. If some adjustment is

necessary, loosen the retaining screws and rotate the

latch springs into the proper position.

NACELLE REMOVAL (FLHR/C)

1. Remove the windshield. See WINDSHIELD REMOVAL

on this page.

2. Remove the Phillips screw at the bottom of the headlamp

door (chrome ring). Remove the headlamp door.

3. Remove the eight Phillips screws to free the headlamp


housing from the headlamp nacelle.

FLTR:

Remove the instrument nacelle.

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT

NACELLE, REMOVAL.

FLHT/C/U:

Remove the fairing cap.

Remove the outer fairing as follows:

a. Standing at the front of the vehicle, use a T27 TORX

drive head to remove the three outer fairing screws

(with flat washers) just below the windshield.

b. Moving to the inner fairing side, remove the two fairing

screws just above the wind deflectors on the left

and right side.

c. Turn the handlebar to the right and remove the outer

fairing screw reaching in below the left side of the

fairing cap. Turn the handlebar to the left and

remove the fairing screw below the right side of the

fairing cap.

d. Tilting the outer fairing toward the front, squeeze the

two external tabs to remove the wire connector at

the back of the headlamp assembly.

e. Lift the fairing (with headlamp assembly) off the

motorcycle.Since the outer fairing screws hold the windshield in


place, the windshield may fall to the floor if not removed.

UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING

CAP, REMOVAL. Remove the radio (or storage box).

4. Remove the left and right handlebar switch controls..

5. Remove upper handlebar clamp screws (with flat washers).

Remove upper handlebar clamps and handlebar.

HANDLEBAR INSTALLATION

Just reverse for install. This is all from the maunual and I hope it helps you.

Most if not all the connectors will have a Phillips head on them. Removal is not difficult but follow these tips and re-installation will go smoother. You do not have to remove the gauges or the ignition nor separate the windscreen from the fairing to remove the fairing. Get out you digital camera(any camera will do) and take frequent pictures as you remove fasteners. If you are unfamiliar with the correct re-installation location use a divided container and label the correct location. There is no trick to remove the fairing. If it won't move after removing the fasteners you most likely have missed some. Follow the pictures for re-installation.

a) new bulb b) remove fasteners between upper and lower fairings so upper fairing can be removed c)remove windshield d) remove mirrors (which hold on upper fairing) e) remove and replace headlight bulb
f) replace everything

Hi there,

well you can please follow the below steps -

Remove the Fairing - 1. Unscrew all seven outer fairing fasteners using a Torx driver. These screws are located on the inner fairing near the windshield, the speakers, and the handlebar clamps.
2. Stand in front of the motorcycle. Tilt the outer fairing toward you and hold it firmly. Reach in and disconnect the wire connectors for the headlight assembly by hand.
3. Move the fairing to a work bench to continue the procedure.

Change the Headlights - 1. Remove the wire harness connectors from the back of each headlight that need replacement. Turn the plastic retainer counterclockwise by hand to remove each bulb from its housing.
2. Install the new headlight bulb or bulbs, with each bulb's wider ears on the bulb back plates oriented toward the top. Screw in the plastic retainer rings by hand.
3. Connect the headlight wire harness connectors to the back of each headlight.
4. Move the fairing back to the motorcycle. Reinstall the fairing, battery and seat in reverse order.
Please post comments if you need more help or information.........

Good Luck!!

Thanks

take the screws that hold the windshield on out, now look on the lower sides of the fairing look for two torqx fastners on the sides remove them and the fairing is off be careful not to drop it