'81 fairing removal


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aznyaz
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'81 fairing removal

Postby aznyaz » Mon May 06, 2013 9:28 pm



I am in the process of sending my carbs out for a rebuild and the shop says I need to move the fairing slightly or remove it completely and I need to know which bolts and/or nuts I need to loosen or remove. They also say the shrouding which is right under the lowers needs to be removed by 3 screws but I can only see 2 that are at the back part of the fairing. Is there also a harness connection that has to be unplugged? They mentioned that as well but the only wiring I can find seems to be only connections for a future radio.

I'm having trouble uploading photos on my home computer so I'll have to do that at work tomorrow, but until then, does anyone have some insite on the fairing removal? Thanks. MJ



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Re: '81 fairing removal

Postby WingAdmin » Mon May 06, 2013 9:37 pm

You do not need to move or even shift your fairing in order to remove your carbs. Remove the false tank and air filter box, unhook the carbs from the fuel and throtte/choke cables, disconnect exhaust runners, and slide them out the left side of the bike.

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Re: '81 fairing removal

Postby littlebeaver » Tue May 07, 2013 7:41 am

I have a 81 and I have never needed to remove or slightly move the fairing to get the carbs out...

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Re: '81 fairing removal

Postby aznyaz » Tue May 07, 2013 8:29 am

Thank you, both. I wasn't thinking last night and should have checked the How-To's. I looked at my bike this morning and found the front mounting bolts for the false tank. Somehow they just didn't register in my mind last night. Will get back on it tonight.

MJ

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Re: '81 fairing removal

Postby littlebeaver » Tue May 07, 2013 9:07 am

At some point you are going to remove that fairing, or is it faring? I can't spell so well.... I have removed my fairing a few times and you should unplug the plug in on the inside of the fairing on the left side and remove the four nuts on the bottom sides...If you have antenias ect. they too need to be unplugged it's kinda a pain in the buttocks at times... Fairing is pretty lightweight though..

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Re: '81 fairing removal

Postby aznyaz » Tue May 07, 2013 9:24 am

Yeah, I was figuring that the nuts on those down-facing studs would be the ones to remove. It appears the fairing just lifts off from there or are there other nuts or bolts to be removed? What about the acorn nuts around the circular edge where the forks come through? (see photo)

I'm also wondering about the wiring. Mine appears pretty simple since I only have the headlight in the fairing. Is the wiring in the photo just for hooking up a radio?
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Re: '81 fairing removal

Postby littlebeaver » Tue May 07, 2013 9:48 am

aznyaz wrote:Yeah, I was figuring that the nuts on those down-facing studs would be the ones to remove. It appears the fairing just lifts off from there or are there other nuts or bolts to be removed? What about the acorn nuts around the circular edge where the forks come through? (see photo)

I'm also wondering about the wiring. Mine appears pretty simple since I only have the headlight in the fairing. Is the wiring in the photo just for hooking up a radio?

Heeeeyyyyy , mine doesn't have that filler there at the forks, I feel as though I have been cheated now,,I want one of those.. I can't tell if it needs to be removed or not but the chances are it doesn't I always wondered what those holes were there for, gosh darn it, you know I gotta find me that part now don't ya? Just because it needs to be there... :D Wow, I learn something new here daily...

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Re: '81 fairing removal

Postby aznyaz » Tue May 07, 2013 9:54 am

I think that piece is there to close off the hole. Pretty sure it's attached to the forks and not the fairing. Those acorn nuts appear to hold something in place as part of the fairing assembly, not an attachment of the fairing to the bracket. What do think out there in forum land?

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Re: '81 fairing removal

Postby Calzone » Tue May 07, 2013 11:26 am

you also need to remove the caps and slides from the right side carbs(right side sitting on the bike) then slide them out the left, sort of like picking a lock, they will come out with a little tweaking.
I also removed my lower faring..maybe that is what they mean by faring.

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Re: '81 fairing removal

Postby littlebeaver » Tue May 07, 2013 11:33 am

Calzone wrote:you also need to remove the caps and slides from the right side carbs(right side sitting on the bike) then slide them out the left, sort of like picking a lock, they will come out with a little tweaking.
I also removed my lower faring..maybe that is what they mean by faring.

Bet you are right, bet that's what they meant....So do you pick alot of locks, do ya? :shock: You're justa lock picken fool ain't ya.. :lol: I always hold my tongue to the left when removing the carbs.. :lol:

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Re: '81 fairing removal

Postby Calzone » Tue May 07, 2013 12:11 pm

One more thing, you need to get 4 containers or paper bags or something to keep the caps with their slides, just take a sharpie and mark 1-4 on the slides and caps,and bodies to mach them up. My technique is to make the carb with the acc. pump #1 and across from it on the other side #2 making a Z pattern.

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Re: '81 fairing removal

Postby aznyaz » Tue May 07, 2013 12:33 pm

Haven't gotten to that part yet but am aware of it and of keeping those pieces with their respective carb bodies. I have also removed the fairing lowers but what really gets in the way are the shroud pieces that are right behind each lower. This is my first carb removal so I'm being a little anal about the whole thing. I'm sure it's simpler than I know.

Thanks for the input.

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Re: '81 fairing removal

Postby Wilcoy02 » Tue May 07, 2013 12:44 pm

You do not need to remove that shield to get your carbs out. The 4 acorn nuts hold the front fairing in place. mine does not have that filler piece either now I want one. When you put the false tank back on leave those 2 nuts in front off. The tank is not going anywhere. Next time you take the tank off it is a lot easier. Mine has been missing those two front nuts for 20 plus years now.

You also have 2 nuts on the bottom by both knees that need to be taken out for the fairing.

Keep us posted on your path...

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Re: '81 fairing removal

Postby WingAdmin » Tue May 07, 2013 9:32 pm

littlebeaver wrote:Heeeeyyyyy , mine doesn't have that filler there at the forks, I feel as though I have been cheated now,,I want one of those.. I can't tell if it needs to be removed or not but the chances are it doesn't I always wondered what those holes were there for, gosh darn it, you know I gotta find me that part now don't ya? Just because it needs to be there... :D Wow, I learn something new here daily...


It's held in there with two Philips screws, and man is it a huge pain to get up in there to remove it. The 1500 has the exact same thing, with the exact same PITA procedure to remove it. It is fastened to (and moves with) the forks.

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Re: '81 fairing removal

Postby aznyaz » Tue May 07, 2013 10:48 pm

Well, I got the carbs off and it was harder than I thought. First, detaching the throttle cables is practically impossible. I can just imagine what a PITA it's going to be putting them back on. Second, there is not enough room to move the carb assembly either left or right to get the caps off #1 and #3 carbs unless you detach the cables first. I was finally able to get them off after detaching the cables and moving the carb assembly to the left, but not before...Third, there is an obstruction from the back end of the fan motor which catches the seam of the plenum. This was a bit of a force job getting the assembly passed the motor but you just have to kind of squeeze it through. Fourth, the last obstruction was my left side engine guard which was easy enough to take off but I was still getting hung up on things (it's hard to tell with every part of the carb assembly going in every direction, exactly what you're getting hung up on!).

Wouldn't it be easier to take the manifolds off of each carb? It seems like with those out of the way it would be easier to get the cables off and also maneuver the plenum/carb assembly in and out. I'd like to hear what you all have to say on that.

I'll be getting the carbs rebuilt, possibly this week or next.

I'll upload more photos and keep you posted as things progress.

Thanks.

MJ

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Re: '81 fairing removal

Postby littlebeaver » Tue May 07, 2013 11:46 pm

Man, if someone instructed you to leave the manifolds on then I just don't know, I always pull them off, and I have zero problems getting the caps off with the cables still connected, the trick is to pull the carbs to the left side as if you are trying to remove them, this will give you access to the cable's lock down nuts, its much easier doing it this way, then just reverse the procedure when installing them....and remember how the cables are routed...

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Re: '81 fairing removal

Postby WINGER3 » Tue May 07, 2013 11:52 pm

When I removed mine I did pull the manifolds, the cables to carbs and choke need to be loosend up as far as you can to get them off much easier. When you are ready to put them back on, I found that if you reach thrue the filter opening to re-instal the cables they are much easier to get back on. Once you have the carbs bolted back up to the underside of filter housing and are going to install the intake runners, grease the O ring grove to keep them in and put the rubber end of the runners in very hot water to soften them up, a little WD40 on the carb ends and the runners will slip right on. Be very carefull that the O rings don't get cought in the valve opening and sucked into the engine. Once you have the runners on you can lift the runner just enough to see the O ring is in the groove befor you bolt them down. Take your time and all will work out. :mrgreen:
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Re: '81 fairing removal

Postby aznyaz » Wed May 08, 2013 6:33 am

In everything I've read about carb removal, nobody has said anything about taking the manifolds off.

Here's a thought then. What if I loosen the clamps that hold the manifolds (runners) on the carbs and just turn them up instead of taking them off completely. That might give the carb assembly a smaller profile in the vertical direction allowing for a little more movement left and right for better access to the cables and taking the caps off. If that doesn't do it then I'll try taking them off completely.

I'll ask the shop when I drop my carbs off what they think.

Here's another observation. When I took the lower part of the air filter box off the plenum there was no gasket between them and none between the filter mount (brass colored metal piece inside the box). The only gasket is on the air filter itself. Isn't there supposed to be an 'O' ring between the plenum and the box?

Thanks again in advance for all the input.

MJ

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Re: '81 fairing removal

Postby littlebeaver » Wed May 08, 2013 10:45 am

You can probably turn them in but I get those things out of my way all together, and I also place some clean rags in the cavities so nothing can fall in by accident.. Here is a blow up of the parts you may want to check on...there is a lower gasket and I found my missing one on ebay..Todd or Road Rogue will probably have one for you, send him a PM or maybe Virgilmobile, he sometimes has a lot of parts in one of his boxes of things ...
Here you go friend...You can go to Bike Bandit for the part number and to blow up the photo.. They probably don't have it though..But it's a great place to look up parts..
Here you go friend...You can go to Bike Bandit for the part number and to blow up the photo.. They probably don't have it though..But it's a great place to look up parts..

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Re: '81 fairing removal

Postby trashtruck » Thu May 09, 2013 9:57 pm

i take the manifolds right off the carb rack also. during installation, if you route the cables on the outside of the frame it makes it soooooo much easier to remove next time.
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Re: '81 fairing removal

Postby aznyaz » Thu May 09, 2013 10:35 pm

I may try that with the cables.




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