ER-6F - Fairing Replacement

[Fat Angry Scotsman]

Well, I thought it would be simple enough to take the old fairings off and put them back on again, but has been a nightmare so far. Current progress (will take pics when I head back down to her, she is sitting in my warehouse waiting on me finishing work again):

1. Got all the fairings off, broke one of those stupid pop fasteners in the process though,

2. Getting it all off was a fucking nightmare. Fuck knows how I am going to do it in reverse because I was helped a lot by the fact the fairings coming off were broken and easily moved,

3. Getting the new wing-mirrors on is going to be a massive pain in the arse as you need to leave them loosely fitted so that you can get the plate that connects the fairings to the bracket and clocks back in first,

4. Getting the fairings off showed me other things that were broken, one thing was the headlight housing is cracked almost completely around it's centre. The only thing that was holding it together was the rigidity provided by the complete fairing assembly and a small part in the centre which is uncracked. I don't want to drop £200 on getting a new one so I absolutely loaded all the cracks full of epoxy and tried to clamp it as best I could with some tight windings of tape. Once it's set I am going to glaze it with a second coat then cut gorilla tape to size and layer it across too,

5. The meter bracket/ mirror stay was missing a screw when I took it off, luckily in my box of random bolts I have an 8mm one that I will put through the hole.

I am currently studying the service manual trying to work out the order that I need to put everything back on the cunt. If I knew it was going to be this finicky I would have just paid some cunt to do it

Somebody once said wrenching on your own bike was fun. Lying bastard

EDIT:

6. Forgot to mention that Amazon sent me the wrong fucking bulbs, some random H1 things and I didn't realise till I cracked the packaging open. Cunts. The current working bulbs stay in the bastard and I get an Amazon refund, I am not waiting for bulbs to turn up in a couple days before putting it back together again.
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PRESENT: 2018 BMW S1000XR SE Sport.
PAST: 2009 Kawasaki ER-6F. 2021 Zontes ZT-125U.

[Nobby the Bastard]

[Fat Angry Scotsman]

[A100man]

ooh my poor ears.. bit sweary today..

but then again you are the Fat ANGRY Scotsman
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600

[Fat Angry Scotsman]

[Freddyfruitba...]

[Fat Angry Scotsman]

Think I am done, got the internal fairing and two side fairings put together.

Manual says the lights and wing mirrors go in next. Can't get it to snug down into the recess as the headlight unit has a cracked lug and I can't force the bottom left down hard enough without flexing the left fairing which I don't want to do because if I fuck that it's game over.

Going to buy a new unit from fowlers and just eat the £240. Guess I have time to get bulbs now eh.

EDIT - Couldn't get it on next day delivery and can't run the risk of having the bike in over the weekend. Bodged it to the best of my ability and crossing my fingers.
____________________
PRESENT: 2018 BMW S1000XR SE Sport.
PAST: 2009 Kawasaki ER-6F. 2021 Zontes ZT-125U.

[Fat Angry Scotsman]

Well this has been a saga but I can see the light coming, here are some pics and descriptions, maybe one day they will help some other poor bastard that made the mistake of trying this themselves.

First, here is the bike with all the shit off. Getting it off was fairly simple and there's other guides on how to do it simply by Googling it.

The main problem I had was with the headlight housing being cracked. Here is my best attempt at bodging a repair - two coats of epoxy resin then taping over the joints with some gorilla tape (whether it does fuck all - who knows?)

https://i.imgur.com/GDyeHcK.jpeg

https://i.imgur.com/q0ZuoMW.jpeg

Getting the headlight back into the fairing was an absolute fucking bastard of a job because of these fucking things.

https://i.imgur.com/c3IbmY4.jpeg

The way I dealt with it was to get the headlight out, put the steel main bracket in along with the wing mirrors, tighten things up but get them loose, then use the bolt that goes through the headlight housing - through the grommet - into the fairing panel as a guide and snug everything down. Then remove the bolt again, like this.

https://i.imgur.com/h8rxlmu.jpeg

https://i.imgur.com/tViYt3c.jpeg

Then you put in the two internal trim pieces which then lets you slot in the upper centre fairing panel that holds the clocks.

https://i.imgur.com/kUO59VG.jpeg

Then you can do the three screws that join the clocks to the main steel bracket.

https://i.imgur.com/luO3BCQ.jpeg

So now I have all the fairings together with the mirrors on. The only things I need to do now are:

1. Move fairings into position, only use three bolts that fix to the frame to hold loosely in position,

2. Re-attached all the electrical connectors and put them back into their little run-clip-things,

3. Use the main bolts to screw fairings into position,

4. Put in the little infill pieces before screwing down all the upper fairings,

5. Screw the lower fairings back on.

Done.

Fuck me I hope this is it and I can see the light at the end of the tunnel. Either that or I am fucking dying.
____________________
PRESENT: 2018 BMW S1000XR SE Sport.
PAST: 2009 Kawasaki ER-6F. 2021 Zontes ZT-125U.

[Fat Angry Scotsman]

Will it fail its MOT because it’s bleeding light through cracks in the back of the housing (the black bit)?

https://i.imgur.com/bkI9SbQ.jpg

https://i.imgur.com/0JXIArx.jpg

https://i.imgur.com/5bRBApk.jpg
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PRESENT: 2018 BMW S1000XR SE Sport.
PAST: 2009 Kawasaki ER-6F. 2021 Zontes ZT-125U.

[UncleFester]

One of your lights is out .... other than that looks like you have faired well .....

*ducks*


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2017 Z1000SX

[Fat Angry Scotsman]

[jeffyjeff]

One little tidbit of wisdom:
Youtube is your friend. Even if you have the repair manual, you can learn a little from watching someone else do the job before you give it a try. Also, you can learn how the grommets and well nuts fit in.

https://www.youtube.com/watch?v=fUdkvnmjg9s
https://www.youtube.com/watch?v=rzMoqUmwyKY

Maybe these videos can help next time (assuming you haven't already seen them),

Cheers.
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History shows again and again how nature points out the folly of men - BOC

[redeem ouzzer]

Did we ever find out how he looped this pile of shite?
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Be a REAL MAN!

[Fat Angry Scotsman]