Remove the black cowling around the shield and headlights? - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 6 Old 10-26-2005, 08:05 PM Thread Starter
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Remove the black cowling around the shield and headlights?

I'm trying to remove my broken black cowling that goes around the windshield and headlights. I have a Service Manual and all it notes is 2 areas with hooks. It doesn't show what they look like or what to do with them, and I can't find what is holding this thing together. I need to seperate the black cowl from the instrument panel.

Anybody know how?

TIA

2004 DL650 - Blue
Yes, a DL650 can definitely do a major smokey burnout!!
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post #2 of 6 Old 10-26-2005, 11:44 PM
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It fits tight and is difficult to remove. You will need to have the side panels off too, along with the windshield, cluster surround, etc... It's basically the piece that holds it all together. There are a couple places where it snaps into, but there are also two screws that hold it to the cluster, they are kinda burried, get a light and a magnetic screw driver and you should be good.
post #3 of 6 Old 10-27-2005, 02:42 AM Thread Starter
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Thanks for your help.

2004 DL650 - Blue
Yes, a DL650 can definitely do a major smokey burnout!!
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post #4 of 6 Old 10-27-2005, 02:45 PM
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It seems to me that it would be easier to remove the entire cowling first , that way you could work on removing the black section without working around the bike front end parts.

I was able to remove the entire cowling from the frame by removing the bolts on each side, disconnect the main electrical cables and remove the bolts holding the cowling to the frame. The previous owner had several lights added to the bike which I didnít feel comfortable trying to cut and reconnect, so I let the cowing sit on my front fender while I removed the air box. If I had cut the electrical wire I could have removed the cowling.

I posted the process for changing the air filter here which included removing the entire cowling.

https://www.stromtrooper.com/forum/viewtopic.php?t=2590

In this picture the cowling is sitting on my fender. You can see the black section is completely exposed and looks much easier to get to.



Just a suggestion, hope it is helpful.

Bill
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post #5 of 6 Old 10-27-2005, 09:53 PM
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I was a little confused by the service manual's reference to hooks. It turns out that they are the same sort of rubber grommets that are on the side panels. If you have removed all screws and the little plastic clips, you just sort of pull on the part so it pops out of the grommets. The trickiest bit for me was disconnecting the instrument panel wiring harness because there were only a couple of inches of room to get my hand between the panel and the cowling.

06 DL-650 - SilverBlue
05 DL-650 - red (RIP - watch your mirrors!)
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post #6 of 6 Old 10-30-2005, 09:28 PM Thread Starter
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Well, I got it all apart. I was surprised at how easy the instrument panel came out (lift a llittle and pull towards the back of the bike). I didn't have any problem unhooking the speedometer, but it was a little troublesome hooking it back up because of lack of space --- and my hands were probably swollen by then from being abused by the Strom engineering0.

But putting it BACK together is the REALLY FUN part. I think I'm going to have some left-over screws when it is all done (hate it when that happens).

Thanks agian for everyone's advice.

2004 DL650 - Blue
Yes, a DL650 can definitely do a major smokey burnout!!
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