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Fairing fitting problem

2K views 9 replies 8 participants last post by  CHAINSAW 
#1 ·
Hi, new member to the forum and the site has a tremendous amount of information. I have a 2003 FLTRI and just swapped out the Radio/Cassette player with a Harmon Kardon unit. The problem I'm having is installing the outer fairing. It appears that the main radio plug is hitting the area just above the slots on the outer fairing and isn't allowing the front radio tray mounting tabs to lock in. The wires on the plug are pushed down and flattened.

Is it possible that the radio tray has been changed on the newer bikes or is it just me.

Thanks in advance you your time.
 
#2 ·
Sure it's possible. But even on a good day there isn't a ton of room behind the headlights. Sure it's a PITA, but I'd dig out the old radio, do some eyeball comparisons with the HK and try to figure out why it worked and the new one doesn't.

Look on the bright side--the worst that can happen is you find out that a very undependable radio that you would probably end up replacing sooner rather than later won't fit.
 
#3 ·
Cant help you with the radio but double check to make sure the outer fairing is hooked to the radio bracket hooks or it wont go back on properly and welcome from CT
 
#4 ·
I'm impressed that you got the wiring for the HK figured out to match up to your 03 harness.

That being said..... the fairing is exactly the same size and shape. Did you change the radio tray, or is it the 03 tray? If it's the 03 tray, you should carve a little away on the outer "ears" because they can wear a hole in the outer fairing. There are a couple thread here about that issue.

But the HK radio, should physically fit in the fairing.
 
#6 ·
I'm impressed that you got the wiring for the HK figured out to match up to your 03 harness.

That being said..... the fairing is exactly the same size and shape. Did you change the radio tray, or is it the 03 tray? If it's the 03 tray, you should carve a little away on the outer "ears" because they can wear a hole in the outer fairing. There are a couple threads here about that issue.

But the HK radio, should physically fit in the fairing.
 
#7 ·
The RG fairing hits the radio mount. Look inside the fairing and see if there is groove cut in the fairing from the radio mount, if there is you need to cut the top corners of the radio mount at a 45 degree angle. You can take JB weld and fill the grooves in the fairing if you want.
 
#8 ·
Welcome from Salt Lake City.

My suggestion along with the others, especially checking the bracket clearance to the inside of the fairing, is to remove the headlight assembly to make hanging the fairing on the tabs easier. Then snap the light assembly in place once the fairing is fastened back in place. Don't forget to hook up the light harness before snapping the lights home or you'll be doing it all over again.

RT
 
#9 ·
Thanks for the welcome and help, the radio tray is for an 03 part number 770780-98, I noticed that this part number changed in 04 to a 98A ending number. Would anyone know what the change was?

My outer fairing is not touching the radio tray, it's the headlight section where the two slots are that mount to the finger brackets. This section of the headlight plastic between the slots is hitting the main wiring plug and the finger brackets won't seat.

Thanks again.
 
#10 ·
If Im reading it right, you will have to reposition your main wiring plug then. Try running it below the fingers to get it out of the way.
 
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