Otis Singleton
Removing the fairing from a Harley Electra Glide is a complex process that requires mechanical aptitude and careful attention to detail. The procedure involves multiple steps, including removing bolts and screws, disconnecting electrical components, and carefully handling delicate parts such as the windshield. While it is possible to undertake this task independently, it is advisable to have a competent assistant to ensure a smooth and efficient process. The removal of the fairing also exposes electrical wiring, fuses, and relays, which requires careful consideration and prior knowledge.
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What You'll Learn
Removing the windshield
First, cover the front fender and fuel tank with a soft towel or blanket to protect the surface from scratches. This precautionary step ensures that the paint job remains intact and is not damaged during the removal process.
Next, locate and remove the screws holding the windshield in place. There are typically three upper screws that need to be carefully loosened or removed. In some models, there may be additional screws on the sides or bottom of the windshield. Make sure to keep a hand on the outer fairing and windshield while removing the screws to maintain stability and avoid accidental damage.
Once the screws are removed, gently lift or slide the windshield out of the fairing. Set the windshield aside in a safe location, taking care not to over-tighten or apply excessive force, as this can cause the windshield to fracture.
With the windshield removed, you can proceed to the next steps of fairing disassembly, such as removing the passing lamp bolts or working on the inner fairing. Remember to refer to a service manual or seek guidance from experienced individuals if you are unsure about any part of the process.
Taking pictures during the disassembly process is highly recommended, as it will aid in reassembling the fairing correctly and identifying any unfamiliar components. Additionally, it is crucial to check the function of all electrical components before starting the removal process. This way, you can ensure that everything is functioning correctly and address any issues during the disassembly.
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Disconnecting the electrical connectors
Firstly, it is important to have a basic understanding of the Harley Electra Glide's electrical system. The bike's electrical connectors are located behind the fairing and are responsible for powering various components, including the headlights, passing lamps, and radio.
Before beginning any work on the bike, ensure that the ignition is turned off, and the battery is disconnected. This step is crucial for safety and to avoid any potential short circuits. Place a towel over the front fender to protect the bike's finish and remove the headlight rim and headlight assembly. This will provide access to the electrical connectors and the back of the fairing.
Now, locate the electrical connectors. They are typically plugged into the back of the headlight and passing lamp assemblies. To disconnect them, gently squeeze the connector and pull it away from the assembly. If the connector is tight, use a 90-degree pick to gently separate the connector. Be careful not to force it, as this can damage the connector or the assembly.
Once all the electrical connectors are disconnected, set the assemblies aside and safely out of the way. With the electrical components disconnected, you can now focus on removing the fairing itself. This will involve removing various screws, bolts, and fasteners that secure the fairing to the bike, as outlined in other sections of this guide.
Remember to take your time and work methodically when disconnecting the electrical connectors. It is helpful to have a basic understanding of motorcycle electrical systems and connector types. If you are unsure about any step, it is always best to consult a professional or refer to a detailed Harley Electra Glide service manual.
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Removing the bolts
First, it is important to gather the necessary tools and materials. You will need a set of wrenches or socket tools to loosen and tighten bolts, as well as a flashlight to illuminate darker areas of the fairing. It is also recommended to have a mild detergent and paper towels for cleaning, and an extra layer of protection for any painted surfaces.
Next, locate the two uppermost Torx bolts inside the fairing. These bolts need to be loosened before proceeding. Be cautious not to over-tighten these bolts, as it may lead to fracturing, similar to cracking glass. Once loosened, you can proceed to remove the three bolts on the top of the outer fairing. With these bolts removed, you can carefully set the windshield aside.
Now, you will address the lower passing lamp bolts. There are two bolts on each side of the fairing. One is slotted horizontally, and the other, located on the passing lamp bracket, is slotted vertically. Remove these bolts, ensuring that you do not cross-thread them. Crossing threads can cause the bolts to pull out of the brass insert, although this is not a catastrophic issue as the inserts are replaceable.
With the passing lamp bolts removed, you can now lift the outer fairing off. Be mindful of the headlamp connection, which is a squeeze-style amp plug. Gently squeeze it to detach the plug. At this stage, the fairing should be loose enough to slide up and out, although some wiggling may be required.
Finally, with the outer fairing removed, you can now focus on the inner fairing bolts. There are four bolts in total, two upper bolts located near the speakers and two lower bolts hidden behind the front fork. Remove these bolts, being cautious not to cross-thread them. With all the bolts removed, you can now carefully lift the inner fairing away.
Remember to take your time, work with someone mechanically inclined if possible, and always refer to the service manual for additional guidance if needed.
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Disconnecting the radio wiring
Before beginning any work on your Harley Electra Glide, it is essential to turn off the motorcycle ignition and allow the bike to cool down completely. This is a safety precaution to prevent any accidental activation of electrical components and to ensure you don't burn yourself on hot engine parts.
Start by removing the outer fairing. This will expose the inner components, including the radio wiring. Be cautious when working around the outer fairing to avoid scratching or damaging the finish. It is recommended to remove the seat by first loosening the fastener on the top of the rear fender with a cross-tip screwdriver. Then, carefully push the seat toward the rear, lift it free, and set it aside.
Now, you can access and disconnect the battery. Disconnect the negative cable from the battery using a 10 mm open-end wrench. This step is crucial to prevent accidental electrical shocks or damage during the radio wiring removal process.
With the battery disconnected, you can proceed to unplug the various connectors attached to the radio. These include the black radio connector, the antenna cable connector (unplug the antenna from the radio), the grey radio connector, and the CB antenna cable connector. Be sure to set aside any connectors that you remove to keep them organised and out of the way.
Once all the connectors have been unplugged, you can remove the four bolts securing the radio to its support bracket. Using a hex key wrench, carefully loosen and remove these bolts. With the bolts removed, gently pull the radio out of its housing.
At this point, you have successfully disconnected the radio wiring and removed the radio unit from your Harley Electra Glide. Remember to keep all the parts organised and safely set aside, as you will need to reassemble them when installing a new radio or fairing. Always refer to the official Harley-Davidson service manual or seek professional assistance if you are unsure about any steps during the disassembly or reassembly process.
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Removing the passing lamps
To remove the passing lamps of a Harley Electra Glide, start by covering the front fender and fuel tank with a soft towel or blanket and disconnecting the battery ground. You can then remove the passing lamp harness by cutting the two tie-wraps that secure it to the lower tree.
Next, remove the passing lamp hardware and carefully rest the assembly on the front fender. You can now unplug the passing lamp connector. There is also a four-pin connector attached to the left side upper fairing bracket on a notch, which powers the turn signals and passing lamps. With the passing lamps unwired, they can be removed completely from the motorcycle as an assembly.
At this point, you can also remove the two bolts on each side of the passing lamp bracket. There is a lower bolt that is slotted horizontally and an upper bolt that is slotted vertically.
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Frequently asked questions
First, loosen the uppermost Torx inside the fairing. Then, remove the three bolts on the top of the outer fairing and set the windshield aside.
Remove the two bolts on the passing lamp bracket on each side. Then, remove the passing lamps and lift the outer fairing off.
Disconnect the radio wiring and remove the radio. Disconnect the throttle and clutch cables from the handlebar perches, then cut the tie straps securing the wiring to the vertical fairing supports. Remove the remaining bracket screws and the four bolts that secure the inner fairing to the fork legs.
Be careful not to over-tighten the windshield as this can cause it to fracture. Also, be careful not to cross the threads on the bolts as this can pull the brass insert out of the ABS plastic.
