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7.4 Bodywork
5.5 Battery panel screws also retain front
of seat cowling
5 lnstallation is the reverse of removal. Note
that the two top screws also retain the front
edge of the seat cowling (see illustration).
Body
pi
removal
anels
-
and insta
General information
Before removing any body panel, study it
closely, noting the position of the fasteners
and associated fittings. In some cases the aid
of an assistant will be required when removing
panels, to avoid the risk of straining tabs or
damaging paintwork.
Once the evident fasteners have been
removed, try to remove the panel as
described but DO NOT FORCE IT
-
if it will not
release, check that all fasteners have been
removed and try again. Where a panel
engages another by means of tabs, be careful
not to break the tab or its mating slot.
Remember that a few moments of patience at
this stage will save you a lot of money in
replacing broken body panels!
Note any fasteners and associated fittings
removed with the panel to be sure of returning
everything to its correct place on installation.
Before installing a body panel, check that
all fasteners and fittings are in good condition
and renew any that are damaged. Also check
that all mounting brackets are straight and
repair or renew them if necessary before
attempting to install the panel. Where
assistance was required to remove a panel,
make sure your assistant is on hand to install
it.
Tighten the fasteners securely, but be
careful not to overtighten any of them or the
panel may break (not always immediately) due
to uneven stress. Take particular care when
tightening self-tapping screws into plastic
lugs on the backs of panels
-
if the lugs break
the panel will have to be renewed.
lubricant (liquid soap o r
mounting grommets
will
assist the lugs to engage without the
need for undue pressure.
In the case of damage to the body panels, it
is usually necessary to remove the broken
panel and replace it with a new (or used) one.
There are however some shops that
specialise in 'plastic welding', so it may be
worthwhile seeking the advice of one of these
specialists before consigning an expensive
component to the bin. Additionally proprietary
repair kits can be obtained for small repairs.
Speedfight models
Handlebar covers
1 The top cover is retained by five screws on
the underside of the handlebars. Access to
the front middle screw is restricted and may
require removal of the front panel (see Step 6)
(see illustrations).
2 Undo the screws and lift the cover to gain
access to the speedometer cable connector
and instrument cluster wiring connectors and
disconnect them, then remove the cover from
the machine. (see Chapter 9).
3 The instrument cluster is retained in the
cover by four screws; undo the screws and
remove the cluster (see illustrations).
4 The lower cover is retained by four bolts.
Undo the bolts to detach the cover from the
handlebars and pull the throttle cable
grommet out of the slot in the lower edge of
the cover (see illustrations). To remove the
cover from the machine, first remove the
handlebars (see Chapter 6). Note the routing
of the cables, hoses and wiring looms before
removing the cover (see illustration).
5 Installation is the reverse of removal.
Ensure that all the connectors are secure and
check the operation of the instruments and
switches, including the brake light switches.
6.la Top cover is retained by two screws
6.1 b
. . .
and one at the front
6.3a Undo the four screws (arrowed)
.
. .
on each side..
.
I
1
6.3b
. . .
and remove the instrument
6.4a Undo the lower cover fixing bolts
. . .
6.4b
. . .
and detach the throttle cable
cluster
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