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I found instructions on how to remove the fairing and used them and added some pics. I don’t know who the author is and I apologize to the author for plagiarizing his / her work. Once I was able to remove the fairing I was able to change the air filter.

Text of instruction

removed the whole front fairing as a complete assembly.

You have to remove:
1. the black L shaped piece on both sides.
2. the small plastic piece at the front of the tank.
3. 3 Allen screws on each side.
4. 2 12mm bolts that fasten the fairing bracket to the frame.
5. un-plug the large plug on the left inside of the fairing.
6. spread the side panels apart and pull the whole thing off.

It is much faster than pulling the side panels off and leaving the
headlights and gauges and everything. You have to reset the clock when you are done though.

The pic are to illustrate most of these instructions. There were some variations to step 5 of these instructions because my bike had been modified by the previous owner. I did not remove the fairing because I had additional wires that I didn’t feel comfortable modifying at the time. So some of the wires you see in the pics you won’t have.

I also did step 5 before 4.

Steps 1,2 are not pictured
Step 3 remove bolts 1 – 4 on both sides. ( bolt 1 is part of step 2) Do not remove bolts 5 and 6





Step 5 “ un-plug the large plug on the left inside of the fairing” . I had three plus to un-plug. The two plugs pictured and a powerlet out let not shown. I don’t know if the two plugs shown are OEM . I could not recognize them as illustrated in the Suzuki DL1000 service manual.



Another view of the plugs



Step 4 “2 12mm bolts that fasten the fairing bracket to the frame”
These bolts are located below the handle bars and triple clamp inside the fairing.



Another view of frame bolts



Once the frame bolts are removed you should be able to remove the entire fairing.

I wasn't able to remove the fairing because of electrical wires installed by the previous owner. But I was able to let the fairing gently set on my front fender while I remove the tank.



View of frame bracket that holds the fairing once faring is removed.





Dl1000 service manual page 4-51 Fuel Tank removed.

At this point , remove the rear fuel tank mounting bolt. Lift the tank and support it on the fuel tank prop stay. Next remove the fuel pump lead wire coupler ( brown connector) . Next place a rag under the fuel feed hose (black connector) and disconnect the connector. Very little gas will came out of the hose. On the right side of the tank is a vent hose , remove this.

Next remove the front tank mounting bolt. Your ready to lift the tank off.





I lifted my tank out without much effort even though it was full of gas.

Tank removed



Next unscrew the 8 bolts from the air box and replace the air filter.


Old filter




Make sure if you replace the old filter with a new one that you remove the O ring from the old filter and install on the new filter



New filter



Once you do it the first time it seems simple. Next put it back together.

Next TB sync

All pics are located here http://wasabi.smugmug.com/gallery/632774/1/26925365[/img]
 

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tank removal

great pics and write up. but i am wondering why you are removing the fairing to remove the gas tank. was there another reason for removing the fairing? i have had my tank off the bike four times now and have not had to remove anything but the two black trim pieces on each side and the black plastic piece that covers up the front bolt on the tank. takes me less then 5 minutes to take the tank off. just curious why you went to so much trouble?
but man that's one hell of a good write up and pics. geezz, i can't even figure out how to post pics. :roll:

Kaos :?:
 
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I scratched the living crap out of my fairing, putting my tank back on!! Boy was I pissed... :evil:
 

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BBurton said:
I scratched the living crap out of my fairing, putting my tank back on!! Boy was I pissed... :evil:
oh geeeezz, sorry to hear about scratching your fairing. i had my beautiful and sensative life partner....." i get points for talking like that" hold the two halves of the fairing apart so i could slide the tank back in. didn't take to much spreading of the cowling halves to get the tank back in.

Kaos :?
 

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Bill, love the annotated tank and fairing!

Reminds me of your "analog GPS"! :roll:

good write-up & photos.
:D
 

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*Great write up and pics!!

I think I'll try it your way next time!! Now If I can only find someone walk me thru my first Valve Adjustment life would be perfect!! LOL!!
 

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Re: tank removal

Kaptain_Kaos said:
great pics and write up. but i am wondering why you are removing the fairing to remove the gas tank. was there another reason for removing the fairing? i have had my tank off the bike four times now and have not had to remove anything but the two black trim pieces on each side and the black plastic piece that covers up the front bolt on the tank. takes me less then 5 minutes to take the tank off. just curious why you went to so much trouble?
but man that's one hell of a good write up and pics. geezz, i can't even figure out how to post pics. :roll:

Kaos :?:
The service manual actually tells you to remove the fairing to get the gas tank off. I got about halfway through removing the fairing and it felt like a lot of work so I checked the MOM section on cleaning the air filter. The MOM tells you to just take off the side panels and the back end of the top black cowling. This works but it can be a hassle trying to push the side fairings out of the way when the tank comes off.

Wasabi's method of getting the fairing out of the way looks easier than the suggested procedure in the service manual.

On the subject of TB synch, the service manual has you remove the airbox and all its connectors, then reinstall the tank, then hook up the various sensors to the airbox. I found that it was impossible to hook the sensors up unless the airbox was more or less in place under the tank. I finally figured out that you had to remove the airbox to easily get to the vacuum nipples on the TBs. Some people have come up with small extension tubes that make it easier to get a manometer hooked up without having to remove the airbox. Once this is done, it was very easy compared to synching the four carb bank on my ZR.
 

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>2. the small plastic piece at the front of the tank.

This is the bit with the plastic rivets (or whatever they are), yes? How in the hell do these come apart? I tried pushing from the back side, but they just bent.
 

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Fast Traveller said:
>2. the small plastic piece at the front of the tank.

This is the bit with the plastic rivets (or whatever they are), yes? How in the hell do these come apart? I tried pushing from the back side, but they just bent.
I had to read about these when I first removed the fairing. Push in the center "plug" so that it slides into the "shell" - the whole plastic rivet can now be removed. Now push the plug so that it sticks out "above" the shell. It is now ready to be reinserted. When positioned, push the plug in so it is flush with the shell to lock it. :D
 

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Gilk51 said:
I had to read about these when I first removed the fairing. Push in the center "plug" so that it slides into the "shell" - the whole plastic rivet can now be removed. Now push the plug so that it sticks out "above" the shell. It is now ready to be reinserted. When positioned, push the plug in so it is flush with the shell to lock it. :D
heh

Simple, eh? Thanks, I'd of done some serious damage if I continued trying to get them out my way.
 
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