04-26-2010, 08:19 PM
Join Date: Oct 2005
Location: Adelaide, Australia
05 to 06 plastics swap
Just completed my fairing swap a couple of days ago.
Here's a list of parts and the things I changed to do this.
19160-MEL-D20 R. Radiator stay
19170-MEL-D20 L. Radiator stay
You can use the 05 Left stay and cut off the bits to hold the fuse and relay boxes, but it's only few bucks.
64543-MEL-D20 R. Middle cowl stay
64544-MEL-D20 L. Middle cowl stay
64547-MEL-D20 Stay Middle cowl
19503-MEL-D20 Hose A Left Radiator
19508-MEL-D20 Hose B Left Radiator
The two hoses are optional. They align the hose with the bulge and cutout in the lower fairing.
I replaced the 05 cam pulse sensor with an 07 one I bought off ebay for $35.
If I hadn't come across this sensor I was going to cut the plug off the wires, cut the socket back on the sensor, solder the wires to the pins and seal with a silicone sealant.
The third option is to cut the fairing in the vent area.
My bike is a late 05 and while doing this mod I found that Honda had already fitted the 06 exhaust headers, so that was a bit of a bonus.
The only cutting I had to do was about 10 mm at the front of the lower fairings, left and right, to clear the slightly bigger 05 radiator and a little bit on the inner fairings to clear a bracket on the radiator.
All the plastic rivets on the 06 are 6mm. The push rivets that join the inner to the outer fairings on the 05 are 8 mm.
I drilled out the holes on the 06 inner fairings to use the larger plastic rivets.
I also found I needed about another 6 to 8 plastic rivets.( 6 mm screw in type, head sits flush )
Fot the heat shielding I used some ceiling insulation wool sandwiched between some silver reflective paper sealed with aluminium tape.
On the right side I ran the ecu wiring loom above the coolant pipe. The ecu is held in an aluminium "U" shaped bracket, bolted to the radiator stay where the coolant bottle should be attached.
The coolant catch bottle is temporary. I'm looking for an aluminium drinking bottle 350 - 500 ml for this.
On the left side the relay box attaches to the inner fairing to the plastic brackets molded onto the panel. Used a dremel to modify the other plastic brackets on the panel to hold the fuse box. The flaper canister and solenoid are gone. The other wiring in the picture is for the fan overide.
There's a third bracket on that side, not shown in the picture (lower right side)