So I'd like to powder coat the lower headlight piece on my 696. I've searched through the forum and found some relevant posts that make it seem very simple, but I've run into a bit of a snag with my bike. The posts I've read say to remove the two screws that attach the bottom of the assembly to the fork. When I went to check out those screws I've found that they're really a nut and bolt combo. That's fine, but there's a tight clearance that won't allow me to remove them with any of the tools I have. My tool collection is relatively limited, so I'd appreciate some input as to what I need to use to properly do this. If you look at the first picture you'll see that there are two bolts in that area. The bolt in the foreground appears to be completely useless. It's not connecting a thing. So 1. what's its purpose, and 2. that 'useless' bolt is blocking my access to the headlight assembly bolt. How do I get to it. Would a simple socket extension do the trick?
Please forgive the white gunk on the trellis frame. I took the sticker off and haven't gotten all the residue off yet.
(http://i371.photobucket.com/albums/oo154/danber0/photo2-1.jpg?t=1243995415)
This second picture is a closeup of the bolt that attaches the assembly to the frame.
(http://i371.photobucket.com/albums/oo154/danber0/photo.jpg?t=1243995414)
Quote from: DanBer on June 02, 2009, 07:31:50 PM
So I'd like to powder coat the lower headlight piece on my 696. The posts I've read say to remove the two screws that attach the bottom of the assembly to the fork. When I went to check out those screws I've found that they're really a nut and bolt combo. That's fine, but there's a tight clearance that won't allow me to remove them with any of the tools I have. My tool collection is relatively limited, so I'd appreciate some input as to what I need to use to properly do this. If you look at the first picture you'll see that there are two bolts in that area. The bolt in the foreground appears to be completely useless. It's not connecting a thing. So 1. what's its purpose, and 2. that 'useless' bolt is blocking my access to the headlight assembly bolt. How do I get to it. Would a simple socket extension do the trick?
Please forgive the white gunk on the trellis frame. I took the sticker off and haven't gotten all the residue off yet.
I suggest you remove that "completely useless" bolt and see what happens when you turn the steering full-lock [bang].... Or maybe don't. This "completely useless" bolt of yours is actually the steering lock adjustment... You'll find another one just like it on the other side. You should NOT remove this item as it actually performs an important role! And nor do you need to remove it to get at the headlight bezel retaining nuts. I suggest that if you cannot remove the nuts with what I call a "ring spanner" and there's no room to get your socket wrench in there (I just did this myself, I dont recall there being any difficulty getting to these nuts... but then I own lots of tools ;D)... then yeah, the thing to use would be an extension for your socket wrench.
Oh and clean that glue off will ya ;)
Thanks for the tips. I'm going to go check it out right now so thanks again.
I don't remember any trouble with those either. If you think those are tough, you ain't seen nothin' yet.
The plug directly above it in the photo is another story... (hint: brains over brawns) ;D
In your picture, one bolt is the steering lock; leave that alone. The other nut is the one you want to remove (10 mm if I remeber right). Remove the similar one on the other side.
Then, lift the headlight assembly up and off of two indexing pins on the upper triple clamp. The headlight basket (assembly) will now be loose (except of course for wiring). At this point, the headlamp access cover is accessible.
CGG