dwhite645
09-02-2006, 03:11 AM
I told the F4i crowd I'd do a write up w/pics on an undertail install. It's not too difficult, but pretty time consuming. The worst part was cutting the plastic oem mud flap because of it's odd geometric shape and thickness variances.
1) remove seat and unbolt seat cowl (10 bolts - 4 in grab bar, 2 top side at back edge below the seat, 1 on each side/low section of cowl, and two plastic snap screws bottom side).
2) remove brake light sockets
3) Carefully remove cowl and don't stress or twist too much.
4) Remove metal retainer for seat lock, slides upward (located on inside of trunk section) and mounting bracket.
5) remove lock cylinder
6) Unbolt turnsignals (under mudflap)
7) Cut turn signal wires close to the turn signal
8) Unscrew brake light lens (4 screws)
9) Put back oem seat cowl and draw a line (I used the edge of masking tape) at the bottom edge of the oem cowl for where you'll need to cut the mud flap for undertail clearance. Then remove cowl.
10) Cut approx 1/8" above line. I used a pnematic cut off tool, but a dremel or hacksaw would also work. Mine was so highspeed that the cuts melted and became rough. It was not an easy task. Be sure not to cut away the screw holes for the bottom section of the cowl from the mud flap plastic.
11) Check fit of undertail with cowl section on bike. Cut more mudflap if needed.
12) With undertail and cowl temporarily set on bike, mark holes in undertail with the holes in the cowl so they align properly.
13) Install license bracket in undertail.
14) Install lock housing, cylinder and retaining clip on inside of undertail.
15) Install lights into undertail.
16) Drill holes for the undertail to be bolted to the cowl.
17) Install on bike and bolt together.
18) Wire according to instructions.
19) Hook up seat lock cable to lock cylinder and check that it works before locking the seat on!
20) Done!
local://upfiles/4409/8613832AEBC84291B33063C69CEE075A.jpg
local://upfiles/4409/8E054D3093E94E27BA11EE352ADB4594.jpg
local://upfiles/4409/55BEE55EC1A943C79242586EB2DD35CC.jpg
local://upfiles/4409/4D707B03FBD14F6CB6AF47411A177368.jpg
local://upfiles/4409/D5EA06720DB44D5BA195B9A4646EC508.jpg
1) remove seat and unbolt seat cowl (10 bolts - 4 in grab bar, 2 top side at back edge below the seat, 1 on each side/low section of cowl, and two plastic snap screws bottom side).
2) remove brake light sockets
3) Carefully remove cowl and don't stress or twist too much.
4) Remove metal retainer for seat lock, slides upward (located on inside of trunk section) and mounting bracket.
5) remove lock cylinder
6) Unbolt turnsignals (under mudflap)
7) Cut turn signal wires close to the turn signal
8) Unscrew brake light lens (4 screws)
9) Put back oem seat cowl and draw a line (I used the edge of masking tape) at the bottom edge of the oem cowl for where you'll need to cut the mud flap for undertail clearance. Then remove cowl.
10) Cut approx 1/8" above line. I used a pnematic cut off tool, but a dremel or hacksaw would also work. Mine was so highspeed that the cuts melted and became rough. It was not an easy task. Be sure not to cut away the screw holes for the bottom section of the cowl from the mud flap plastic.
11) Check fit of undertail with cowl section on bike. Cut more mudflap if needed.
12) With undertail and cowl temporarily set on bike, mark holes in undertail with the holes in the cowl so they align properly.
13) Install license bracket in undertail.
14) Install lock housing, cylinder and retaining clip on inside of undertail.
15) Install lights into undertail.
16) Drill holes for the undertail to be bolted to the cowl.
17) Install on bike and bolt together.
18) Wire according to instructions.
19) Hook up seat lock cable to lock cylinder and check that it works before locking the seat on!
20) Done!
local://upfiles/4409/8613832AEBC84291B33063C69CEE075A.jpg
local://upfiles/4409/8E054D3093E94E27BA11EE352ADB4594.jpg
local://upfiles/4409/55BEE55EC1A943C79242586EB2DD35CC.jpg
local://upfiles/4409/4D707B03FBD14F6CB6AF47411A177368.jpg
local://upfiles/4409/D5EA06720DB44D5BA195B9A4646EC508.jpg