How do I remove nose plastic? - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

 
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post #1 of 9 Old 06-06-2016, 09:31 AM Thread Starter
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How do I remove nose plastic?

I bought my '09 KLR 650 used and the previous owner must have dropped it as the nose is slightly tweaked. It's not noticeable standing still but when riding you can definitely tell it is cocked. How do I remove the front nose plastic so I can stick a pry bar in there and straighten it out?

John "JohnBG' Grocke

2009 KLR 650
2006 Ural Raven (Patrol) 2WD

Love is the feeling you get when you like something as much as your motorcycle.” ― Hunter S. Thompson
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post #2 of 9 Old 06-06-2016, 09:59 AM
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Here's the scanned section out of the service manual for removal of the upper fairing. It's the 2016 manual, but hopefully not too far off steps-wise. I've had the upper fairing off and don't recall having to remove the headlight assembly, as mentioned in the details. Rather, I left it in, disconnected the leads and slid the nose off with the headlight assembly still in there.

I've had to do this exercise before. While you've got that all apart make sure your forks, triple tree and bar are square. It's a good time to square all that up too.

Hope pdfs attach.

Good luck!
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File Type: pdf Upper Fairing.pdf (203.6 KB, 15 views)
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post #3 of 9 Old 06-06-2016, 10:07 AM Thread Starter
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Quote:
Originally Posted by Bill10 View Post
Here's the scanned section out of the service manual for removal of the upper fairing. It's the 2016 manual, but hopefully not too far off steps-wise. I've had the upper fairing off and don't recall having to remove the headlight assembly, as mentioned in the details. Rather, I left it in, disconnected the leads and slid the nose off with the headlight assembly still in there.

I've had to do this exercise before. While you've got that all apart make sure your forks, triple tree and bar are square. It's a good time to square all that up too.

Hope pdfs attach.

Good luck!
Thanks! Do you need to take the lower plastic off first?

John "JohnBG' Grocke

2009 KLR 650
2006 Ural Raven (Patrol) 2WD

Love is the feeling you get when you like something as much as your motorcycle.” ― Hunter S. Thompson
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post #4 of 9 Old 06-06-2016, 10:14 AM
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Working from memory here. The step-by-step doesn't have you removing the lowers to get the upper fairing off. However, iirc I had a problem accessing one of the bolts or fasteners on the upper fairing and ended up removing them. The lowers do need to come off anyway if you end up removing the upper fairing bracket to work on straightening it.
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post #5 of 9 Old 06-06-2016, 10:25 AM Thread Starter
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Quote:
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Working from memory here. The step-by-step doesn't have you removing the lowers to get the upper fairing off. However, iirc I had a problem accessing one of the bolts or fasteners on the upper fairing and ended up removing them. The lowers do need to come off anyway if you end up removing the upper fairing bracket to work on straightening it.
OK, got it. I figure if I can get the plastic off I can use a pry bar to straighten it out, right?

John "JohnBG' Grocke

2009 KLR 650
2006 Ural Raven (Patrol) 2WD

Love is the feeling you get when you like something as much as your motorcycle.” ― Hunter S. Thompson
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post #6 of 9 Old 06-06-2016, 10:47 AM
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OK, got it. I figure if I can get the plastic off I can use a pry bar to straighten it out, right?
Well, I'd say before prying or bending anything, see what the problem is. Then I'd suggest that you try and avoid prying or bending anything. Loosening bolts and fasteners and realigning parts might be the path to get your problem solved.
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post #7 of 9 Old 06-06-2016, 12:28 PM
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There are four Allen head bolts that have to come out, the headlight connector need to be removed, and the two turn signal connectors need to be undone to remove the cowl.

The cowl needs to be rocked from side to side a bit to clear the dash.

Two bolts are in the dash, two are under the cowl just forward of the gas tank.





Tom

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Last edited by Tom Schmitz; 06-06-2016 at 12:37 PM.
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post #8 of 9 Old 06-06-2016, 01:08 PM
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Tom,
Looks like you have a double posting. But that is not why I'm posting!

Is that an oil pressure gauge on the L.H. side of that dash??
Friends bike? Or did ya' buy a spare bike? Maybe you got tired of changing tires, from dirt to street and back again?

pdwestman
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Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #9 of 9 Old 06-06-2016, 01:44 PM
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I don't think I've ever had more trouble putting up a post. Took me 40 minutes.

Nah, that's a thermometer and a clock.

This was back when I was swapping things from my '08 to my '09, way before the oil pressure testing started.

Tom

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“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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