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Discussion Starter #1
i TRIED to install the chicom headlights and a new windvest tonight. For the life of me i could not get the fairing back on, the sides (next to the glove departments) would not seat with the inner. I tried so many times im fairly sure i stripped 1 hole out.
 

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The only way the outer fairing will sit properly is if it's on the hooks on the radio bracket. Once on the hooks you'll be able to align the tabs. As far as stripping out the holes, it happens and in case you don't know, there are 2 longer screws and 4 shorter ones. The threads can be repaired. What I do is once aligned properly and the other screws are snuggled up, I inject the hole with quick dry apoxy, spray the screw with WD40 and thread it all the way into the hole gently. Let it sit for a minute or so then unscrew it, wipe of the WD40 and thread it in and out a couple times then snug it up. I've had great success doing it this way as I've repaired a couple of the threads
 

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After your sure it's center hooked, Finns (glove box edge) are meshed right, I'll lighty install the the bottom (not tight) ...

Before drawing the outer into the inner, I learned to...
Spot light the holes visually plus use a small Allen wtench, ice pick or anything that works to make Sure it's the hole your putting the screws in and not the side molding of the hole
 

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i TRIED to install the chicom headlights and a new windvest tonight. For the life of me i could not get the fairing back on, the sides (next to the glove departments) would not seat with the inner. I tried so many times im fairly sure i stripped 1 hole out.
View this YouTube video. I always go to YouTube first for all my endeavors.

https://www.youtube.com/watch?v=BvwSsWefj9A
 

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if you have to force something on that you didnt have to force off, then its time for a break, nap, meal anything to just step away from the bike and then once you return you head should be a little clearer to tackle the job, that is unless you use that break time to get your drink on lmao
 

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The side fins are not lapped right if the fairing is on the hooks right.
 
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if you have to force something on that you didnt have to force off, then its time for a break, nap, meal anything to just step away from the bike and then once you return you head should be a little clearer to tackle the job, that is unless you use that break time to get your drink on lmao
I used to (have to) tell my son all the time that the key to the thing is the 'Carefully Applied' usage of excessive force ... Don't just commence to whaling on it.
 

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I used to (have to) tell my son all the time that the key to the thing is the 'Carefully Applied' usage of excessive force ... Don't just commence to whaling on it.
yes sir im still telling my oldest son that who happens to be a mechanic at Hyundia lmao, but ill never let him touch my cars lol
 

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Unscrew the headlight and install through the holes.

This was the key for me. remove the headlight assembly from the fairing....then its TOTALLY easy to hook the fairing on. THEN snap in the headlight assembly.
 
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The only way the outer fairing will sit properly is if it's on the hooks on the radio bracket. Once on the hooks you'll be able to align the tabs. As far as stripping out the holes, it happens and in case you don't know, there are 2 longer screws and 4 shorter ones. The threads can be repaired. What I do is once aligned properly and the other screws are snuggled up, I inject the hole with quick dry apoxy, spray the screw with WD40 and thread it all the way into the hole gently. Let it sit for a minute or so then unscrew it, wipe of the WD40 and thread it in and out a couple times then snug it up. I've had great success doing it this way as I've repaired a couple of the threads
name brand and pictures of that epoxy! I've spent the past 2 years screwing with stripped fairing bosses and have even bought a replacement fairing off the forum to replace the factory one. I've tried almost everything, but it sounds like you've found the magic elixir. Please share video evidence to support your claim!!! LOL
 

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name brand and pictures of that epoxy! I've spent the past 2 years screwing with stripped fairing bosses and have even bought a replacement fairing off the forum to replace the factory one. I've tried almost everything, but it sounds like you've found the magic elixir. Please share video evidence to support your claim!!! LOL
JB weld work just as good. The trick is DON'T OVER TIGHTEN THE SCREWS. That means if there is a gap don't try to pull the inner and outer fairing together with the screws, pinch the fairing together with your fingers first then screw in the screw until it is lightly seated.
Always make sure the inner/outer fairing side fins are lapped correctly before you try to install screws. :wink:
 
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name brand and pictures of that epoxy! I've spent the past 2 years screwing with stripped fairing bosses and have even bought a replacement fairing off the forum to replace the factory one. I've tried almost everything, but it sounds like you've found the magic elixir. Please share video evidence to support your claim!!! LOL
Ironmark is right. Don't try to pull the gap closed with the screws and snug is all you need. Also remember that there's 2 long screws and 4 short screws. Here the picture of what I use. It's not the cheapest stuff but I like it. It comes with 3 static mix needle injectors which works nice to inject the apoxy into the thead hole while the fairing is in place on the bike. The only problem with this is the static mix needles are basically a one time use. Once you take the needle off the apoxy tube you throw it away because you aren't able to keep is apoxy in the needle from hardening. I buy this from my local Napa auto parts store [URL=http://s1073.photobucket.com/user/rlaf75/media/20160725_102648_zpsolhgkz1s.jpg.html][/URL]
 

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JB weld work just as good. The trick is DON'T OVER TIGHTEN THE SCREWS. That means if there is a gap don't try to pull the inner and outer fairing together with the screws, pinch the fairing together with your fingers first then screw in the screw until it is lightly seated.
Always make sure the inner/outer fairing side fins are lapped correctly before you try to install screws. :wink:
I've tried JB weld on numerous occasions and found it just doesn't hold up for me on plastic. As a helicopter mechanic for over 20 years, I have used it very successfully on metal, but it just doesn't seem to bond as well to plastic. I've had the fairing on and off many times and always (just like chopper work) use the manual each and every time, so I always watch out for the fins and any wire looms that may obstruct the fit.Thanks for the reminder though. I think most of my problems come from the 19" windscreen and the amount of pressure it exerts on the fairing right at the top of the outer due to the excessive amount of air force pushing on the top of the windscreen. That and the inherently piss poor design of the fairing system to begin with!
 

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Ironmark is right. Don't try to pull the gap closed with the screws and snug is all you need. Also remember that there's 2 long screws and 4 short screws. Here the picture of what I use. It's not the cheapest stuff but I like it. It comes with 3 static mix needle injectors which works nice to inject the apoxy into the thead hole while the fairing is in place on the bike. The only problem with this is the static mix needles are basically a one time use. Once you take the needle off the apoxy tube you throw it away because you aren't able to keep is apoxy in the needle from hardening. I buy this from my local Napa auto parts store [URL=http://s1073.photobucket.com/user/rlaf75/media/20160725_102648_zpsolhgkz1s.jpg.html][/URL]
Thanks for the pic's. I'll give it a try this weekend.
 

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by the way Rlaf, Have you tried cleaning out the tip with some 0.020 or 0.032 safety wire or a needle in order to salvage the tips? Seems like a waste to have to throw away the tip after each use.
 

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by the way Rlaf, Have you tried cleaning out the tip with some 0.020 or 0.032 safety wire or a needle in order to salvage the tips? Seems like a waste to have to throw away the tip after each use.
You actually can't run anything down the needle. Because it mixes as it's passed through the needle it has little twisty thingy inside to intertwine the 2 parts of the apoxy. You'll see what I'm talking about if you buy it. There's other stuff out there that's similar but I happened to have a buddy that had this on hand so I used it. I liked it and went out and bought my own to have and I've used it twice. Three times if you include stealing my buddies
 

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Discussion Starter #19
well that pretty much sounds like exactly what i did, tried to pull it together with screws. I let it sit for the night and was able to get it sun morning after we got home. Thanks all for the help I will fix the hole this weekend. I wish I had more time to ride and tinker then work.
 

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I've tried JB weld on numerous occasions and found it just doesn't hold up for me on plastic. As a helicopter mechanic for over 20 years, I have used it very successfully on metal, but it just doesn't seem to bond as well to plastic. I've had the fairing on and off many times and always (just like chopper work) use the manual each and every time, so I always watch out for the fins and any wire looms that may obstruct the fit.Thanks for the reminder though. I think most of my problems come from the 19" windscreen and the amount of pressure it exerts on the fairing right at the top of the outer due to the excessive amount of air force pushing on the top of the windscreen. That and the inherently piss poor design of the fairing system to begin with!
I used JB weld to repair the stripped screw hole with great success. You just have to do it right, first of all get some cooking spray and spray the screws and let it dry, then mix the JB weld and pack the stripped screw hole, then insert screws while turning them into the soft JB weld, make sure to wipe away excess JB weld, let the JB weld cure and then remove screws by unscrewing them. The cooking spray acts as a release agent so it is important that you use it.
The windshield size has nothing to do with the side screws stripping , the windshield size has more effect on the wellnuts.
 
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