08 Upper Cowl Removal

h82loze · Nov 11, 2008

Since this was requested and no one has posted a write-up yet, I decided I would. This doesn't take that long, as long as you are pretty good at removing the mid-cowls/side fairings. After you remove them a few times, it's not that hard.

I have also listed torque values. If I missed any, someone please add them in.

1. Remove the mid-cowls/side fairings and upper inner covers-see this thread:
http://www.1000rr.net/forums/showthread.php?t=46051&highlight=ram+air

2. Remove rearview mirrors (pictures below are for the right side-procedure is the same for the left side)
Pull down rubber/plastic boot (located between the upper cowl and upper stay behind the nuts) and disconnect the 2 connectors (red arrows)

Unbolt 2 10mm nuts-red arrows pointing to them (7 ft/lbs)

3. Remove windscreen
Remove 4 3mm bolts (1.1 ft/lbs) shown by red arrows

There are 2 tabs at the front of the cowl that go to the 2 front grommets in the stock windscreen that you will need to slide the windscreen off of. Or you can just break those 2 tabs off when you pull off the stock windscreen to replace it like I did. Don't know about other aftermarket windscreens, but the Puig I have doesn't even have those front 2 grommets, so I didn't care if I broke them or not.

4. Disconnect sub harness 20P and 8P connectors-red arrows (left side of bike)

5. Disconnect vacuum hose from one-way valve
That's the ugly brownish-gray hose in the previous picture. Just yank it off from the one-way valve under the upper cowl

6. Remove upper cowl from frame grommets-pull the upper cowl forward
The next 2 connectors are the only thing holding the upper cowl to the bike now

7. Disconnect the horn connectors and the combination meter connector (tachometer/speedometer connector)-red arrows (the combination meter connector is already disconnected in this picture-it's covered with a boot which is the blurry thing in the foreground of the picture

Installation is the reverse of removal.
Hope this helps.

Grey Fox · Apr 17, 2011

hi everyone, hope ya'll are doing well. this is my first post and had a question that i am hoping someone would be able to help me with. I'm currently in the process of changing my upper cowl and have the service manual, but am unable to disconnect the 20P and 8P subharness. no matter which way i apply pressure to the tabs i cant get them to disconnect. these two cables are the only thing preventing me from completing my bike. if anyone would be able to help, i would be most greatful. thank you very much.

TedEbear · Apr 17, 2011

Grey Fox said:
but am unable to disconnect the 20P and 8P subharness. no matter which way i apply pressure to the tabs i cant get them to disconnect.

Okay, I just went down to my basement and unplugged mine to verify the following. You press the tabs inward, don't pull or pry outward. On the 20P there's only a tiny bit of the tab to press on. It is easy enough to press but you may have to wiggle the plug back and forth as you press the tab and pull the connector apart.

On the 8P, press near the center of the locking tab, not on the end of it. You might have to wiggle it as you pull it apart but it is not as tight of a fit as the larger plug.

BTW, welcome to the site. :th_salute:

Grey Fox · Apr 17, 2011

Thank you very much. i appreciate ur advice as well as the welcome. been spending hours playing with it. had to replace my left mid and upper fairing after an accident last summer. woman driver with a cell phone and dog on her lap, lol. hope you have a good weekend. thank you.

1000rrelkman · May 15, 2011

Help with bolts on the inner trim panel

I just got done with changing my upper that broke when washing. When I put it back together I went to install allen bolt in the inner trim panel at the base of the upper and there is nothing for it to screw into. It was removed in step 2.

2. Remove the allen bolt on the inner trim panel at the base of the upper on each side.

I think this is the spot with the two rubber grommets that I transferred from the old cowl. Could I leave these out? Seems to be used to hold the inner trim panel and it is pretty solid anyway.
Thanks

OH81KRR · May 18, 2011

Did it today and this was a very helpful post. only took me about 20 mins to swap out my upper. thanks guys

tx04rr · Jun 21, 2011

Thanks for the detailed instructions, I will be replacing my broken one this weekend

IcedTEE89 · Jul 12, 2011

Good write up. Very sticky worthy. Thanks H82loze.

pmhitman · Mar 20, 2012

cluster help

Anybody in so cal close to Ontario ca that has their front cowl off I have a cluster that I wanna see how many miles it has

2003csl · Mar 24, 2012

not a bad right up. thanks

peoples_champ · May 8, 2012

i actually needed to put it on after crashing my bike so this was very helpful, i just reversed the steps lol

Mastermind · Aug 21, 2012

I have broken one of my mirrors and I'm considering on using block off turn signals like I had on my old gsxr. Has anyone spotted these LED turn signal block offs for an 08 cbr1000?

phobos512 · Aug 21, 2012

I believe this is what you're looking for. And these are painted rather than powdercoated or anodized so assuming you pick the right color they should match your fairings perfectly.

Chrisj0806 · Dec 13, 2013

Life Saver!

suth101 · Mar 25, 2014

Bikes crazy 2 take appart

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08 Upper Cowl Removal

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