Kawasaki Service Van Visit to Meerut/Mawana - 04-06-2018
Warning - Long Detailed Post/s ahead once again - Only for Enthusiasts
I was thinking of getting all these accessories fitted and was planning to open up the fairings, one of the tricky jobs in the book, myself. And voila, I receive a call from Swapnil, the Service Manager at Aurum Kawasaki, that Kawasaki was planning to send it's Service Van FREE OF COST
to Meerut and Mawana as a Customer Drive Initiative. The running cost of these vans including diesel cost is borne by Kawasaki India (IKM). The Customer is usually charged for any jobs done on his bike at the showroom/service center rates. Aurum, anyways, had to install my frame sliders free of cost. So I jumped on this opportunity to get all my other jobs done as well. Panniers fitting I had already completed myself.
So the planned jobs
, which involved opening up the fairing, were - PUIG Po Frame Sliders Install, K&N High Flow Air Filter Install, Bosch Symphony Horn Upgrade from the Windtones, Dual Power Cable Install, LED Indicator Bulbs Upgrade - Front and Back, LED compatible Flasher Relay change from a static 40W capacity one to a variable 0.6W~150W one, etc.
So the long body Force Traveller reaches Meerut and sets shop outside my residence
The van is fully equipped with a dedicated tool set of workshop specs and space to even carry 1-2 bikes if needed
Yours truly with the Service Technician Mr. Ramdev and his assistant cum van driver
The first job is to remove both the seats and set them apart. Notice the soft cloth laid on the floor to carefully place all fairing parts to avoid any damage or scratches.
Now Opening of the Fairings
is the main job today. Though the Technician said he was well versed with the procedure, I will lay down a few videos which helped -
This PUIG Pro Installation video directly from the company was MOST helpful as it details the procedure exactly for our bike
Also helped by this video by our fellow enthusiast and Ninja 1000 Owner Jonathan Long -
So the first job is to remove the one middle fairing bolt and one plastic quick rivet from the middle fairing
on the left side
Then it is pulled back and then forward to release the projections, tabs and hooks as shown in the picture, and the middle fairing is off
Next job is to remove the Side Cover
on the left side by removing the 2 bolts, one at the back as shown and one at the front and then pull it outwards to clear the projections carefully
. Special care has to be taken to remove this side cover as I have seen technicians crack this plastic cover if care is not taken.
Next job is to remove the Lower Fairing
on the left side. More detailed photos of the same during the re-installment process. Remove the 2 quick rivets from the inside side
And also the two at the bottom
Then on the left side, disconnect the turn signal light connector as visible in the photo and also the Outside temperature sensor connector (behind the turn signal connector and not visible in the photo). Then there are 2 bolts at the bottom (on the left side fairing), two on the top front and one on the top rear. After removing these 5 bolts, the fairing is pushed outwards and then back to slide the fairing off.
The original Denso, Japan 40W static load flasher displayed here, which will be removed as with LED bulbs, it doesn't detect the load and it is engineered to think that a bulb has blown off, and starts to flash quickly to warn the rider. This has to be replaced by variable load Flasher which blinks constantly even at lower or higher loads. Something like this can be got from Custom Dynamics USA
for 20$ here - https://www.customled.com/products/e...-flasher-relay
or for a fraction of that cost from AliExpress from where I have got it (link already posted before). Left Side Fairing Removal is now complete
Another view of the left fairing removed Right Side Fairing Removal
starts with the middle fairing as done on the left side
Right Side Lower Fairing also involves removing one of the lower metal plates near the exhausts, which the technician is now unbolting
Right side middle fairing - right side indicator turn signal connector being removed Right Side Fairing is now removed
similar to the left side one. Notice the 3M Paper Tape attached to the exhaust mounting to avoid any scratches while removing the metal lower fairing part from the right side (only)
2 upper tank bolts are now being removed by the technician to access the air filter below the tank.
This video helped in accessing the Air Filter to install the K&N Air Filter
The Tank just slides upwards after removing the 2 Tank bolts as marked by the position of the arrows in the picture
The overflow drain hose is also removed from it's clamps and socket to free the tank to slide upwards
The main fuel hose is also removed after sliding the red lock forward and sliding the fuel hose from the outlet pipe as shown in the picture. This also facilitates easy swinging up of the fuel tank. No fuel leaks as the fuel tank cap is closed.
The Air Filter Housing
is revealed below the tank
There are 11 bolts to be removed to access the air filter. The connector bracket (as marked by the arrow) is also slid upwards to detach from the air filter housing.
The last (11th) bolt is tricky and sits deep inside the housing as marked in the picture
Now the Upper Air Cleaner Housing is free and is removed to reveal the air filter and the inlet valves
The beautiful 4 cylinder Inlet Valves of the Throttle Bodies. Warning
- Take special care to cover them up with clean cloth so as to avoid anything going inside them. This will lead straight to engine damage.
Top View of the Stock Air Filter (outlet side visible covered by metal mesh) and the throttle bodies
The Stock Air Filter View (inner side) from inlet side. Lots of debris is visible which is subsequently cleaned. As the rated life of this filter 12k kms, it still has a life of about 10k kms left in it. It is thoroughly cleaned and stored for emergency. Also note that even though it is a paper mesh filter, it is also red in color, and is hence oiled slightly to catch dirt better.
The air intake chamber is revealed where intake air is received from both the functional side (left and right) vents on the bike
The air intake chamber is thoroughly cleaned to make it ready to receive the K&N Filter
30 Photos limit reached. To be continued...