How to remove front fairing assembly (head lights and fearing) from 03 VFR800?

Discussion in 'Mechanics Garage' started by Cacique2002, Dec 5, 2009.

  1. Cacique2002

    Cacique2002 New Member

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    I am trying to remove the front fairing assembly from the bike but I cannot figure out what else to remove. I have already removed all other fairings (left and right lower fairings, lower fairing and upper side small fairings).
    Please let me know what to do next.
    thanks
     


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  2. Cacique2002

    Cacique2002 New Member

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    ok, i figure it out, there are two 10mm nuts that need to be removed and then the hole thing (front fairing and lights) come out.
    Now I need to remove the gas tank. I see there are 4 bolts (two in the front and two in the back of the tank. After removing those whats next? I guess I must empty the tank.
     


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  3. crustyrider

    crustyrider New Member

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    epting the tank will make it easier....you won't run the risk of fuel leaking out all over the place when you pull the fuel line off....

    Are you rebuilding the bike?
     


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  4. stoshmonster

    stoshmonster New Member

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    Before you do anything with the gas tank Cacique,take the seat off,disconnect and remove the battery and get it away from the bike.
    Gas fumes and ignition sources in close proximity to each other is never a good thing.

    Draining your gas tank as completely as you can before you start this job also helps.

    Remove the two bolts that secure the front of the gas tank,lift it up slightly and remove the bolt that secures the steel stop cable on the left side frame rail. That way you'll be able to pivot the tank open as far as possible. You can either prop the tank up or you can have a helper hold it for you.
    Get some old rags and lay them beneath the fuel hoses at the back of the gas tank. That way you'll catch any stray fuel that you might spill.
    Take a look at this pic. The Red arrow points to the fuel return line. If you remove this hose and there's fuel still in the tank it will just come gushing out and continue to keep gushing out until the tank completely empties itself. The Green arrow points to a quick-disconnect "drybreak" that I installed in the fuel return line. Take a pair of surgical clamps and clamp the hose off and cut it,a pair of needle nose visegrips with a couple of sockets on the jaws works just as good,and install a "drybreak" in that fuel return line. By doing this one simple modification you'll be able to quickly and easily disconnect the fuel return line from your gas tank and spill maybe a drop or two of fuel at the most,and it won't matter how much fuel you have in your gas tank either.
    [​IMG]

    Now that you've got the fuel return line taken care of you'll need to remove the banjo bolt on the high pressure fuel supply line. The Yellow arrow in this pic points to it. Prepare yourself Cacique,that little basstid is FAT torqued on there. (FAT torqued = Fuckin' A Tight torqued) Breaking the torque off that banjo bolt can be a bit of a knuckle-buster Cacique,just so you know. Again make sure your rags are under the hose because it will spill a little bit of fuel when you remove the hose. Don't lose the two little washers that are on the banjo bolt either,you'll need those. Empty the fuel from the hose into a bucket and cap the end of the fuel hose with a plastic baggie and tape it up. Lay that fuel hose off to the side then disconnect the Brown electrical connector for the fuel pump and the Blue electrical connector for the fuel float. The Red arrows in the pic point to those two connectors.
    [​IMG]

    There are two hoses at the front of the gas tank,the overflow and breather hoses. On my bike those hoses were held to the underside of the tank by a foam pad. Those two hoses snake down the left side of the bike between the frame rail and the motor. Simply pull those two hoses up and let them hang off to the side,they'll go with the gas tank when you remove it. If those two hoses on your bike aren't trapped by that foam pad under the tank,just remove them and lay them off to the side.
    [​IMG]

    Set the gas tank down. At this point you can either remove the two bolts at the back of the gas tank or remove the two Black plastic side covers and remove the locknut and hinge pivot bolt for the gas tank. Now the gas tank will simply lift straight up and off the bike. If there's still fuel in the tank be careful because that gas tank can be a bit awkward to carry. The more fuel in the tank,the more awkward it is to carry.
    Hope this helps you Cacique. Good Luck.
     


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  5. Cacique2002

    Cacique2002 New Member

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    man, i wished i would have waited and then read your posts!!!
    well, i got it done anyways.
    since I am going to paint the bike and needed to remove the fuel pump and filter from the gas tank, so what I end up doing was i removed all four bolts from the gas tank, placed a 5gal oil container next to the bike and I moved the gas tank from the bike and place it vertically on top of the oil container and started to loosen the six 10mm nuts that hold the fuel pump and then the gas started coming out and accumulated inside the oil container, no spills and simple. waited for the gas tank to empty (I had about 1/4 of a tank, I know I should have used the bike for a few miles before doing this, but we had snow and I was bored to death at home!!!).
    now I just need to tape off a few things and take all the part to my friend for a fresh paint job.
    How should I prep the gas tank, I guess just cover the upper filler hole and the two bottom holes (fuel pump hole and gas level hole).
    thank guys
     


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