This Chapter covers the procedures necessary to remove and install the body parts. Since many service and repair operations on these motorcycles require the removal of body parts, the procedures are grouped here and referred to from other Chapters.
In the case of damage to the body parts, it is usually necessary to remove the broken component and replace it with a new (or used) one. The material that the body panels are composed of doesn't lend itself to conventional repair techniques. 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.
When attempting to remove any body panel, first study it closely, noting any fasteners and associated fittings, to be sure of returning everything to its correct place on installation. In some cases the aid of an assistant will be required when removing panels, to help avoid the risk of damage to paintwork. Once the evident fasteners have been removed, try to withdraw 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 or to damage the paintwork. Remember that a few moments of patience at this stage will save you a lot of money In replacing broken fairing panels!
When Installing a body panel, first study it closely, noting any fasteners and associated fittings removed with it, to be sure of returning everything to its correct place. Check that all fasteners are in good condition, including all trim nuts or clips and damping/rubber mounts: any of these must be replaced if faulty before the panel is reassembled. Check also that all mounting brackets are straight and repair or replace 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 the uneven stress.
Where trim clips are used, to release them unscrew the centre of the clip, then pull the body of the clip out of the panel When installing them, fit the body of the clip onto the panel then push the centre fully into the body. As they are made of plastic, the threads easily become worn and the centres may not unscrew, in which case lever the centre out of the body using a small screwdriver.
Note that a small amount of lubricant (liquid soap or similar) applied to the mounting rubber grommets of the seat cowling will assist the lugs to engage without the need for undue pressure.