Possible Broken Piece

[Brocked]

Hey everybody I need your help on this one! Let me start off by saying I have no technical experience with fixing cars/motorcycles at all. That being said one of my headlights went out so I said "Well I'm not paying 60 bucks to get that fixed! I'll do it myself!" So I bought the bulbs and went about trying to replacing them without taking off the fairings.

Took my 20 minutes to get the old bulbs out (should have taken 1 minute) but I got them both out. Replaced the bulbs and went to fit them back in. Got them in and was desperately trying to get the metal clasp back over the bulb when *pop*

http://imgur.com/miE2Bfq
http://imgur.com/mnA50wd

****!!!

So my question is did I break this piece off or does it come out somehow? And if I did break it off, what the hell do I do now?

PS: I couldn't get either bulb back into its clasp, I'm that bad. And after it snapped I tried taking the fairing off and got 13 bolts/screws out and it wouldn't budge. Very frustrated.

[NevadaWolf]

Oay, first question, when you say one of the bulbs went out, which one? The ninja runs one bulb on low beam and then both bulbs on high beam, so if you were on low beam and the throttle side bulb was "out", that was how it's supposed to be.

But now, the clip. That is what holds the bulb in place. Doesn't look like it broke, but came off.

Were you able to get the front cowling off? How far did you get if you weren't able to?

Gimme a sec to round up a video that shows how to get that clip back in place.

[csmith12]

Don't look broken to me, just needs to be put back in place.

[Brocked]

The left bulb went out on me so both were gone on low beams, didn't test high. I would be relieved if it just slipped out and not broke, I didn't think I put to much pressure on it...

As for the fairing, no I wasn't able to get the front cowl off. I started out trying to remove that and then moved on to working of the side panel. No like either way. I couldn't find the (possible?) screw on the inside of the fairing and couldn't get the plastic pieces to come apart (most notably the circular plastic piece that holds the two side fairings together at the bottom of the bike).

This is my very first try at anything even remotely like this so I appreciate the help, I seriously lack experience.

[NevadaWolf]

Ok, so we'll start with the fairings. The covers on the bike need to be taken off in the right order. So here's a DIY for removing the plastics.

http://www.ninjette.org/forums/showthread.php?t=9933

[NevadaWolf]

Once you get the front cowl off and can look at the back of the headlight, this is *similar* to what you'll see though this is for a pregen. But this has the clip in place which may help replace it.

[Brocked]

Ok from what I can tell I can within 4 pieces of getting it off. Those plastic rivets through me for a loop honestly, and that last bolt up in the "plastic tunnel looking thing" eluded me.

I feel confident I can get the 4 pieces in the DIY off within 30 minutes or so. Once I have them off, do I try to remove the front piece or should I be able to get my hands on the headlights without many issues?

[NevadaWolf]

I would remove the front just for ease of access and to truly see what's going on up in there. It's just as simple to take off and put on again as the others.

[NevadaWolf]

BTw if you scroll down the DIY you'll see pics for the front cowl and further down for the tail. Keep that link handy for the future (or its stickied in the Tech Section).

[Brocked]

I appreciate the help! I'll have a few hours to work on this tomorrow, and sadly it will probably take up that entire time haha. I will update with the results!

[NevadaWolf]

Originally Posted by Brocked

I appreciate the help! I'll have a few hours to work on this tomorrow, and sadly it will probably take up that entire time haha. I will update with the results!

No problem, that's what all of us are here for.

The first time I took all the plastics off, it was sort of intimidating. But after having done it numerous times now, I can get them off in about 15 minutes or so. The part I hate the most are the plastic rivots on the bottom, followed by the two screws in the black tunnel under the radiator. Everything else, cake walk!

[Brocked]

Update: Well it took about 2 and a half hours but I actually did it! Got all three pieces off without major incident (did lose a plastic rivet from the underside of the fairings, thing shot off and was impossible to find).

Here she is naked: http://imgur.com/1HDnNwK

Here is the bulb clasp fixed with two new bulbs: http://imgur.com/1RdFzrI

And put all back together (with no extra pieces laying around haha): http://imgur.com/KJ7fAOR

Also had to fill up my coolant, even though I paid through the nose for a dealership to do it 2 month ago and they apparently lied to stupid me.

Overall it was actually pretty easy although time consuming. Just goes to show that someone who has never done anything like this can do it without to much hassle. Thank you all again for the help, especially you Nevadawolf, I will be doing this again in the future to do my own maintenance for sure.

[NevadaWolf]

Whoo hoo! Congrats!!

Great working on your own bike, since only you are personally invested in it working correctly and being up to snuff. Those fairings will come off easier and quicker from now on.

I just learned how to change my own oil (and break the drain plug - don't ask) so we're all learning as we go.

[JohnnyBravo]

Congrats on getting it fixed up