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1993/1994 Outer Fairing and Windshield for FLHTC, and FLHTC ULTRA
Removal
First remove the headlight assembly and the bolts, nut and the washers attaching the outer fairing piece to the windshield and inner fairing piece. THEN loosen the four bolts attaching the light bracket and the outer fairing piece to the fork brackets. Remove the upper bolts but leave the lower ones in place. Cover the fender. THEN rest the lower light bracket onto the fender. THEN remove the fastener securing the headlamp trim ring and remove the trim ring. THEN remove five screws that secure then headlamp assembly to the outer fairing and remove the headlamp assembly. THEN reach through the headlamp opening and loosen four locknuts on the two studs on each side of the headlight area which attach the fairing to the metal brackets inside the fairing. THEN remove the fairing by pulling it straight ahead away from the brackets.
Installation
First loosely position the outer fairing in place over the inner faring with the four studs going into the two brackets. Then install the five windshield fasteners through the outer fairing, the windshield and the inner fairing. THEN tighten the four stud nuts to secure the fairing to the brackets, being sure to have the inner and the outer fairing properly aligned at their outside edges. THEN position the light bracket so that the slots fit around the upper fork bracket bolts and thenalign the lower fork bracket mounting holes and replace the two lowering fairing mounting bolts through the light bracket and the outer fairing and the inner fairing and screw them into the lower fork bracket. THEN make sure that the rubber seal around the inner fairing is properly seated and not pinched and tighten the four fairing attachment bolts to 12-13 foot pounds (16 -19 Nm). THEN tighten the windshield screws to 4 inch pounds (0.45 Nm) but no more than this amount starting in the middle and working outwards on both sides. THEN reinstall the headlight assembly.
You may have answered your own question, check the connections under the fairing, use a test light probe on the wiring and work backwards until you find problem.
There is a thing that acts like a pop rivit tool only it puts a threaded nut in the hole. Ask at your full service Ace Hardware store or other fine retailer in your area.
I think this will solve your trouble. You may have to drill out what is in there now.
Take outer fairing off,3 torx screws on windshiald 2 more under mirrors or close to it and 2 more at bottom.these can be very difficult to put back in.take your time and do not tighten untill all have been threaded.dont use to much pressure as brass inserts can pull out.once you have the outer fairing off you will see brackets on inner.this is common on your bike(and mine too) I believe the torx is a 27.Hope this helps you
There usually are additional fasteners that can be found when the headlight assembly is removed, I have an older model and there are four nuts on studs that are attached to the outer fairing tightend onto a frame work between the two halves. Once these are loosened the front assembly slides forward.
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