Front Right block-off plate

[dan_h2sx]

So on sunday I pulled off the fairing to see this:

These are the first three points where the cover is secured.
The two on the right are easy acessible, the one on the left is a bit of a pain but it's still doable.
The one screw on the left also seems to hold the headlight assembly in place but I figured you could just pull the cover out somehow.

Then I stumbled onto this, which cause a major problem (at least to me):

This is the forth screw holding the duct cover in place. There is no way in hell to reach that screw except dissasembling the entire (!) front end of the bike

I really don't wanna do that as it's such a high effort for such a small detail that bugs me.
Do you think there is any other way of removing this part? (Without breaking anything)

Well maybe I'll do it during off-season

I'm still thinking of ordering a spare part, just in case. I'll figure out something eventually

[Burmashave]

I think that lets me out, too. :-(

It's hard to tell from the picture, but just to confirm, is that space too tight for an offset screwdriver, or a phillips bit held by a small vice grip?

[dan_h2sx]

It's way to tight. You might have about 5mm / 0,19 inch of space between the head of the screw and the headlight-housing. If you had a philips bit that small, maybe but then again how do you grab it let alone apply enough power to unscrew the damn thing?

Oh, and how'd you get the screw out? I don't now how long it is, but the other two have the same length. If this is the case and all 4 screws are equally long, then it's simply not possible to unscrew the cover w/o taking basically everything apart.

I'm still on it though, as I've just ordered the service manual from the U.S.. It should arrive until mid of june, then I'll have a look what steps really are necessary to remove our 'beloved' duct cover.

[Champ87]

It should arrive until mid of june, then I'll have a look what steps really are necessary to remove our 'beloved' duct cover.

For what you're trying to do, the job will be much easier if you remove the nose fairing. I removed the duct cover temporarily for a recent project. I don't think I had to remove the headlight but, if you do, you will have much more room to work and try different ideas for replacement of the duct cover. With fairing off, the headlamp bracket is easily removed (6 screws) and the headlight is even easier (4 screws).

Removing the nose fairing seems like a major pain the first time but becomes much easier when you've done it once. The factory Service Manual has good detailed description of removal. A few months back I posted a Fairing Removal Aid which you may find helpful.

This photo shows inside the fairing with the headlamp bracket (and attached faring bracket) and headlamp unit still in place. In this picture the duct cover itself isn't visible because I used it to mount the controller for my keyless ignition system.

[dan_h2sx]

For what you're trying to do, the job will be much easier if you remove the nose fairing. [...] A few months back I posted a Fairing Removal Aid which you may find helpful.

You are my hero! Although at the moment I find it rather scary to remove the nose fairing due to the fear of breaking something / not getting it back together, but I'm quite positive, as you mentioned, that the service manual will be of great help.

Also I'm gonna consult your fairing removal aid, that comes quite handy, thx mate!

Gonna order the duct cover in two weeks, got a tour planned
I'll keep you updated!

I still think its more of a winter project to be fair though

[Burmashave]

A few months back I posted a Fairing Removal Aid which you may find helpful.

Champ, your guide and a few other pieces of reference info should be put in a closed reference forum, along with the service manual pdf, etc. I forget that newer members may not be aware of them.

[Champ87]

Champ, your guide and a few other pieces of reference info should be put in a closed reference forum, along with the service manual pdf, etc. I forget that newer members may not be aware of them.

Obviously, I would agree with that if our site admin wants to setup a reference forum/thread. We do have the Specs section that contains the H2 SX Gearing Spreadsheet so maybe that could be organized to contain various pieces of reference information - and make it more obvious what's in there. For now I just use opportunities to make members aware so, in that spirit, I'll use the great opportunity your post provides. Thanks

Fairing Removal Aid
Shared Parts
Torque Settings
Wiring Diagram in Glorious Color (US, CA and CAL)
Wiring Diagram in Glorious Colour (for H2 SX SE other than US, CA and CAL)

I recently changed front and rear sprockets so I'll post up something on that soon. Another good candidate is vcyclenut's H2SX Easy ECU Removal video

[Prof J]

Does the piece vent air into the bike, or is it a false cover kinda thing? (I'm supposed to pick my bike up this next Monday-so won't know until then.)

[dan_h2sx]

It's a false cover.

[Prof J]

Ya know, from looking at photos, bike will be here Monday so I don't have good info, it looks like, from the side profile of that duct, horizontally it forms a "V", with the apex of the "V" pointing to the engine area, on both sides/both 'ducts'.

If it were not much to relocate, I might consider relocating the electronic items behind the duct, and then just fab'ing up a piece of aluminum, but only for the top portion of the "V", leaving out the bottom portion. This would effectively then channel all for incoming air right into the upper portion of the radiator, and I'd think helping keep the bike cooler. The thermostat will maintain the 'temp' it needs to, anyway, but the extra air may likely push off any extra heat. You'd still have that upper plate you fab'd up - which could be made to have a pocket behind it, to mount some electrical stuff, and seal those things off.

I wouldn't do it if I could not do both sides that way. If an intercooler were mounted, and both sides were fab'ed, that could really help an intercooler, but for me, a few thousands dollars for say 5 or so HP, is questionable, unless someone is racing or the like. I'd probably do it just to keep the extra cool, as I use to live in the desert, and going between Las Vegas and the upper desert in Calif, near Barstow, it gets pretty hot in the summer days.