ive had my '94 for 8 months now its done 27000kms thereabouts and i have put about 6000kms of commuting, touring and some pretty hard high speed stuff so ive gotten to know and been able to identify some rattles and buzzes.
so ive set out to rectify these an i thought i would see if i can make a difference for the buzz box
when i first had the fairings off i noticed the PO had used garden hose to mount the windscreen instead of the original moulded rubber bolts which has been contributing a fair bit to the rattle but as i didnt have the parts to fix it and i was using the bike everyday she went back together as it was..
also at around 6000revs the two metal grills at the bottom of the fairings would rattle as their spring retaining clips (after 19 years) have become loose..
the six hex head bolts for the windscreen were an easy fix straight off Ebay for around $20 shipped and because the fairing bolts also have the same moulded rubber bolts to mount them i ordered another 6 to c if they would sort out some of the vibration between the fairing and the tank..
The two grills were a little more involved...
Tools needed
10mm ratchet ring spanner
4mm allen key (hex key)
long Phillips head screw driver
fine tipped flat blade screw driver
pliers
box spanner
Materials needed
alchohol based cleaner ( wax n grease remover will do fine)
sikaflex (marine grade silicone sealant/adheasive)
first remove the windscreen ( 6 hex bolts ),
lift away the clear section,
remove the six rubber plugs from the inner plastic (these will most likely need replacing) remove the inner plastic to reveal the back of the instrument cluster and 2 more hex bolts that will need to be removed to take the fairing off.
remove the two hex head bolts behind the winscreen and two on either side of the fairing (six in total)
using your long phillips head remove the four (2 on each side) inner mounting screws that are on either side of the headlight inside the guard.
the fairing should now be loose
remove the fairing carefully, i found it easier to turn the bars when removing and stretch the back out A LITTLE... and it will slip past the indicators.
once thats off inspect where the six hex bolts went into if the rubber is volcanised replace them.
here is a photo of two new rubber with the 19 year old one in the middle.. BIG difference
i used a small flat blade to carefully bend the tabs of the grill retaining clips back trying not to snap the moulded plastic posts (use pliers later to flatten back out so they can be reused.
once the grills are removed give them a clean and a paint as they will not be coming back off in a hurry, and give the inside of the fairing a good clean too as the sikaflex will need to bind well to both.
i used the grills to make a quick guide line to follow so i didnt put the sealant everywhere. then did a 2mm wide piping of sikaflex around the edges of the fairing.
press the grills down into the sikaflex so it comes through the weaves.
re install the retaining clips, i used a box spanner to do this but any narrow rigid tube would work, im sure a large pen with the ink removed would work just fine.
leave over night......
and thats where im up to..
also whilst the fairing was off i found it easy to go for a ride and adjust the headlight...
ill have the fairing back on tomorrow but i gave the grills a tap in place a little while go and all seems very promising
anyway ill keep you posted
dave