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Discussion Starter · #1 ·
Ok, yes, yes I am a moron, but that’s not the point. Are the lower front fairing bolts a Royal PIA to get lined up, or am I stupid, or is my bike just weird? I already stripped one, pretty sure another is about to strip. I’ll get in there with a tap and see if I can fix it later, but I want to ride and it’s a KLR, so I just zip tied it for the moment. Maybe I’ll just leave it like that, all my previous KLRs had zip ties somewhere on the bodywork.
 
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Discussion Starter · #3 ·
I love those special features…
 

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If I recall, I needed to screw in the very bottom just a bit first, align the other big bolt, screw in lightly. start putting the upper little bolts that go into Well Nuts lightly. Then tighten all but not too tight. Yeah the two big lower bolts need a little gentle persuasion to align. If I feel them too tight, I back off and try again.
 

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I have had my right side off twice, both times I found getting those 2 large bolts to align required considerable pushing, shoving, and patience.
 
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not too familiar with the current Gen plastics but can you maybe start with the difficult one?

and only just start the fastners until you have all the hardware installed, then start tightening
 

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No. You are not a moron. I have a Gen. 2 and I've had issues with those panels as well. The best way I've found to eventually get them back on is as a4twenty had mentioned above. First off, take a deep breath and relax, you're not in a pit race. I've found that when I'm in a big hurry to get something done like this it ALWAYS takes me twice as long to get it done.

Relax, go slow, and when you can snatch the small stones from my hand it will be time for you to leave Grasshopper. 🦗
 

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I've RE-Bent many of factory brackets back into proper alignment. Most caused by even very minor tip-overs.
 
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2022 Pearl Lava Orange
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Don't do like I did while reinstalling the fuel tank and accidentally get the left side fairing inside the fuel tank tab and scratch the crap out of the fairing. Eehhh, gives it character.
 

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It's not just you - As Paul had mentioned, a couple of good hits can knock the brackets out of alignment which makes fairing removal/install a pain - and it's worse working around (behind) the engine guards. Oh well... I do what OCL recommends and get the bolts "just threaded on a wee bit" and then button it all down tightly once everything is in place.

My fairings are so cracked, epoxy-fied, and duct-taped that scratches wouldn't be noticed - I think it's got character, too.
 

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2022 klr, lava pearl, medium tusk panniers, thermobob, happy trails upper and lower crash bars.
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I've had both sides off a few times, it's definitely a pain, but I find it easier if I start with the bottom ones first, and do the Phillips in the wheelwell last.
 
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