Monday, November 4, 2013

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How to Remove a Fairing 2000 Ultra

How to Remove a Fairing 2000 Ultra

Properly speaking, there are two fairings on the front of a 2000 FLHTCU. The big batwing that protects you from the wind when you get in the wind is the outer fairing. It, with the windshield, attaches to the rest of the chassis with a total of seven screws. Once it comes off the inner fairing remains. The inner fairing holds the instruments, radio, stereo speakers and other amenities Harley sells with Electra Glides. It is also easily removed by unfastening just four screws. There are a few steps before a rider can reach those last four screws, however.

Instructions

    1

    Drape a folded blanket over the front fender and wheel to protect the finish.

    2

    Loosen and remove the three Torx screws just below the windshield in front of the fairing and the two screws just outside and below the speakers inside the fairing with a Torx head driver.

    3

    Expose the two outer fairing screws just below the fairing cap on the right and left side by turning the handlebars all the way to the left and all the way to the right. Loosen and remove both of them with a Torx head driver.

    4

    Remove the wire connector at the back of the headlamp assembly by simultaneously squeezing both sides of the connector with your fingers and pulling. Straddle the front of the bike and lift the fairing off with both hands to expose all the wiring harness connections beneath. Lift the loose windshield off the front of the motorcycle.

    5

    Pull the turn signal connectors apart into halves. Pull the passing light connector apart into halves.

    6

    Unfasten the passing light bracket from the forks with a Torx head driver and remove the passing light assembly.

    7

    Turn the ignition key left to "unlock." Turn the cam shaped ignition knob right to "access."

    8

    Slide a small screwdriver under the ignition knob and push up the release button under the left side of the knob. Push the key down, turn the knob left and lift the knob off the rest of the ignition switch to expose the switch post and switch nut.

    9

    Loosen the switch nut with a small combination wrench and pull the nut, spacer and collar off the switch post. Pull the broad chrome skirt on the bottom of the inner fairing up and off.

    10

    Loosen the clutch cable adjuster nut and the clutch cable adjuster lock nut on the clutch cable near the left down tube with two combination wrenches. Completely slacken the clutch cable.

    11

    Remove the clutch control pivot pin and retaining ring with a flathead screwdriver. Loosen the clutch lever bracket with a Torx head driver and remove the clutch lever from the bracket.

    12

    Disconnect the clutch cable from the end of the clutch lever. Feed the clutch cable through the weatherproof grommet in the bottom middle of the inner fairing.

    13

    Cut a small square from a typical, 1/8 inch thick cardboard, produce box and insert the square between the front brake lever and the brake lever housing to protect the stop signal plunger from damage. Remove the switch housing and master cylinder from the right side of the handlebars with a Torx head driver.

    14

    Pull the throttle off the right end of the handlebars using a flathead screwdriver. Disconnect the idle and throttle cables wrapped around the inside end of the throttle.

    15

    Feed the idle and throttle cables through the weatherproof grommet in the bottom middle of the inner fairing.

    16

    Disconnect the cigarette lighter from the exposed wiring harness. Loosen and remove the six speaker adapter screws with a Torx head driver. Remove the speaker adapters.

    17

    Disconnect the fuel gauge and voltmeter from the exposed wiring harness. Loosen the four screws that hold the inner fairing to the fairing bracket with a Torx head driver.

    18

    Pull the bottom of the inner fairing and slide it off the mounting pegs. Pull the bottom of the fairing mounting bracket to free it from the mounting pegs.

    19

    Pull the inner fairing from the mounting bracket and remove the inner fairing.