05 to 06 plastics swap - Honda CBR1000 Forum : 1000RR.net
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post #1 of 74 Old 04-26-2010, 07:19 PM Thread Starter
GRD
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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)
Attached Images
File Type: jpg IMG_6204a left side.JPG (141.5 KB, 260 views)
File Type: jpg IMG_6209a right side.JPG (151.1 KB, 277 views)
File Type: jpg IMG_6198.JPG (188.3 KB, 175 views)
File Type: jpg IMG_6206.JPG (153.2 KB, 169 views)
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post #2 of 74 Old 04-26-2010, 07:25 PM Thread Starter
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Here's some pictures of the finished product.
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File Type: jpg IMG_6490.JPG (212.4 KB, 265 views)
File Type: jpg IMG_6500.JPG (216.5 KB, 258 views)
File Type: jpg IMG_6506.JPG (213.8 KB, 230 views)
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post #3 of 74 Old 04-26-2010, 07:27 PM
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sick paintjob! Where did you get the 07 swingarm, or is it powdercoated?
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post #4 of 74 Old 04-26-2010, 08:52 PM Thread Starter
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Swingarm is powdercoated. Cost me $45, cheaper than getting another swingarm
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post #5 of 74 Old 04-26-2010, 08:57 PM
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Did you HAVE to move the ECU wires? Most say they didnt move them. Were yours keeping the fairings from fitting?
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post #6 of 74 Old 04-26-2010, 09:18 PM Thread Starter
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I didn't try fitting the fairing with the harness in the original place.
It's not a big deal to move the harness.
Just undo the coolant hose from the pipe, unclip the harness from the frame ( two plastic plugs) and move it above the coolant pipe.
If you do this you get a couple of inches of harness to play with because it goes around the cam chain tensioner in it's original position.
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post #7 of 74 Old 04-26-2010, 10:40 PM
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Thanks for the reply. I need all the help I can get right now. Ive got HIDs to fit in as well sp its a tight fit inside the fairings.
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post #8 of 74 Old 04-26-2010, 11:08 PM
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I like the color combo! What fairings did you use, oem?
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post #9 of 74 Old 04-27-2010, 02:40 AM Thread Starter
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The fairings are Auctmarts.
The nose, tank and tail piece bolted on just like the originals.
The left and right fairings needed a little pushing and pulling to get on but all the holes linned up and the fit is good.
Bringing the two halves together and joining up with the small inner guard under the radiator took a bit of doing and I ended up using a couple of bolts and two plastic rivets to hold it all that together instead of just four plastic rivets. I've read about this problem with other fairings. Do the fairings all come from the same maker???? I don't know the set up.

The paint looks realy good no runs just a very minor blemish (looks like a colour touch up under the clearcoat, only noticable in certain light at certain angles) but I'm not sure how tough the paint is and how it will stand up to normal use e.g. bugs dust and road grime. Seems a little soft to me.

Can any one thats had a set on their bike for more than 6 months comment on this?

Dealing with Auctmarts..........now thats quite an experience.
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post #10 of 74 Old 04-27-2010, 09:14 AM
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Quote:
Originally Posted by GRD View Post
Dealing with Auctmarts..........now thats quite an experience.
Have you had trouble with them? I ordered the 06-07 fairings from them as well but any question Ive had they answered promptly.
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