ElectricMotorcycleForum.com

Tomorrow's Early Tasks

Jack the bike up
Dismantle the Triple Clamp
Hope the Fairing Arrives
Pray I didn't forget anything and need to ride out to get it...

Is that a 6.6kW chargetank?

Next fit the U collar around the headstock, tabs pointing downwards. Like this:



Then Bolt the fairing mounting, at this point READ THE INSTRUCTIONS about the wiring, because its a few steps down and it's a pain to unbolt everything to sort the wiring out.
Also MAKE SURE the dash cable is nice and untangled, because it's also a pain to undo everything a second time to untangle that from the rest of the loom.

Not that I had these problems you understand, it's just that, errr, I'd hate to see other people make this mistake.

If your install looks like this at this point,

its is wrong, and you will have to unbolt everything and start again

Next post - Putting the fairing bracket on properly?

Time to start assembling things.
First off the dash.



Note these brackets are a REAL tight fit to the Fairing mount. I'd have liked about 1mm more clearance on the bolt holes on the fairing mount. But everything fitted - just...
Otherwise I'd have had to alter the holes on the milling machine. Fine for me, but not everyone has a milling machine in their workshop.



And, pop the Dash Console on, nice and easy.
Note: if you don't have a 10mm deep M8 socket to hand, then a short 8mm spanner will allow you to get the Console off and back on. Its tricker, but doable.

Fit the Left and Right Fairing supports...

*

...and the headlight (plus the lower bracket I forgot to take off earlier), and it's starting to look more like a bike, and less like the result of a head on collision.


Note, at this point I'd spotted that I needed to install the Rok Risers, that's what you get for starting the work before the fairing kit arrives in the post!
So don't forget to install the risers, as you might find it hard to steer the bike without them.

Second note.
At this point, if you are using the OEM wing mirrors. Put them on about now . It's pretty hard ( read impossible ) to put them on when the fairing is installed without removing either the fairing, or the handlebars...

(sorry no photos at this point, I forgot to take my phone into the workshop. )

Not much else to say, fitting the heat set plugs was a breeze, (and don't worry about the plastic splitting like in the instruction photo, just use a tiny bit more heat, a steady hand and not to much pressure and it wont split, I promise)

Drill out any extra holes for the windscreen, I recommend drilling out the extra two at the bottom. Makes everything a bit more rigid. 

Fit the tank and fairing, drill the holes for the upper mounts, and BOOM, fairing installed!


Add for some finishing touches, and its beer and pizza time.

Damn, that looks great!

I wrote the instructions, so thanks for pointing out the critical omission. I'll get that into the latest revision today.

Cheers, and happy to help.


So anchor bolt failure post mortem, and my potential fix.

The problem:

There appears to be an 11mm gap between the T Bracket and the bottom of the lower triple clamp. No idea if this is intentional, but I've rechecked the instructions and the positioning of the main fairing bracket and everything seems kosher.

I'd tensioned the T bracket against the lower triple clamp, this formed a spring. The residential road I was riding along was a bit bumpy, and that naturally caused the T Bracket to spring the anchor out.


There is no physical way of lifting the fairing bracket any higher than I mounted it, that I can see.




Solution:

120 year old technology to the rescue. Using my ancient 19thC lathe (they built them to last back then!) I created a 9mm spacer out of Engineering Nylon66 that I happen to have lying around (I love my workshop)

(The stem in the chuck was cut off later of course... )

This was then used to pad the space between the T Bracket and the Lower Triple, allowing me to tension the anchor without adding any spring tension to the T Bracket.



Good idea? Bad Idea?

Thoughts?