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Old 05-28-2012, 11:25 PM   #1
bouson   bouson is offline
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Adding a Harley Tour Glide fairing to a Vulcan

Adding a Harley Tour Glide fairing to a Kawasaki Vulcan is a fairly easy thing to do.


I'll try to explain this, it wasn't all that difficult when I started thinking how to do it. So here goes


The wiring can be done using Harley parts (available at dealer for around $15 total) spliced on to the Kawasaki wire harness (I left all Vulcan wiring plugs attached in case I decided to take the fairing off sometime).


The fairing only has 3 mounting points;
1 is the bracket that runs from behind the headlight inside the fairing to the neck area of the frame.
The other 2 are the brackets that attach to the bottom rear of the fairing and the engine guard/crash bar (SEE PICTURES THAT FOLLOW).


The fairing on the Harley sets forward because of the front end design on the Harley and only weighs around 27 pounds. I shifted the fairing back about 3 inches by using the Harley bracket front hole for the crash bar bracket as the rear hole for the Vulcan setup (SEE PICTURES THAT FOLLOW). This also redistributes the fairing weight on the bike more evenly and improved the handling of the bike.


The bracket behind the headlight is a box without a top or one end (SEE PICTURES THAT FOLLOW). I had a friend weld one up for around $20 metal include. I also opted to use grade 5 bolts and fender washers instead of studs on the front. The bottom stud wasn't used in this application. The legs of the box sides that go around the neck of the frame were made long enough to share the same bolts that held the wiring harness (I upgraded those bolts to grade 5 steel). One hole was drilled in the frame in front of the the wiring harness bolts and aft of the neck (SEE PICTURES THAT FOLLOW). This holds most of the weight so I used a 3/8 inch grade 5 steel bolt to hold it and with the front of the U that the legs make resting against the front of the neck and the weight of the fairing pushing down the lever effect makes it all stable with the other two brackets. Also there is a bolt I added in front of the neck to pull the top of the box in tight against the frame (Friend use thin metal stock I suggest 1/8 steel at least)


The rest is prep and paint to personal taste.


If you have any questions ask away and I'll try to answer them in a clearer way.
Attached Images
File Type: jpg LBrcktF.JPG (44.3 KB, 69 views)
File Type: jpg LBrcktR.JPG (48.1 KB, 63 views)
File Type: jpg OrS.JPG (32.9 KB, 62 views)
File Type: jpg OrT.JPG (27.6 KB, 57 views)
File Type: jpg OrTB.JPG (27.9 KB, 56 views)
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My friends call me KC!!
Wichita, KS
VBA #02089

In order installed:
Audio Adaptor Kit
Mini Air Pump
After market 132db horn
Barefoot Willies "Cool Rider" Cup Holder
Garage Door Opener (ala Gadget's Website)
16" Kawasaki Windshield
Door Trim to stop Gas Tank Cover Rattle
Single Schrader Valve Setup (ala jestephens)
Non-bike stuff:
Kawasaki Banner in Garage
Previous Bikes:
75 Yamaha 175
09 Vulcan 900 Classic
Harleys:
75 Sportster XLCH
84 Sportster 1000
85 FXRT
79 Low Rider


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Last edited by bouson; 05-28-2012 at 11:34 PM. Reason: Forgot about bolt in front of neck.
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Old 05-28-2012, 11:31 PM   #2
bouson   bouson is offline
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Adding a Harley Tour Glide fairing more Pictures

Adding a Harley Tour Glide fairing more Pictures
Attached Images
File Type: jpg RBrcktF.JPG (44.8 KB, 51 views)
File Type: jpg RBrcktR.JPG (34.8 KB, 46 views)
File Type: jpg Wiring.JPG (45.4 KB, 52 views)
File Type: jpg DSC8.JPG (56.1 KB, 78 views)
File Type: jpg DSC10.JPG (67.2 KB, 72 views)
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My friends call me KC!!
Wichita, KS
VBA #02089

In order installed:
Audio Adaptor Kit
Mini Air Pump
After market 132db horn
Barefoot Willies "Cool Rider" Cup Holder
Garage Door Opener (ala Gadget's Website)
16" Kawasaki Windshield
Door Trim to stop Gas Tank Cover Rattle
Single Schrader Valve Setup (ala jestephens)
Non-bike stuff:
Kawasaki Banner in Garage
Previous Bikes:
75 Yamaha 175
09 Vulcan 900 Classic
Harleys:
75 Sportster XLCH
84 Sportster 1000
85 FXRT
79 Low Rider
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Old 05-28-2012, 11:59 PM   #3
Monkeyman   Monkeyman is offline
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I tried it and couldn't make it work. Glad to see you did. Unless you already have the turn signals, I'd suggest ditching the early TG fairing and buying a later one (post-'86 or '88, I think) that DOESN'T have the integrated signals. The originals (and nobody makes aftermarket) integrated signals are about $250/pr IF you can find them.

Perhaps I was over thinking my mounting brackets but like I said, I just couldn't make it work. Congrats to you for getting it done!
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Old 05-29-2012, 12:29 AM   #4
bouson   bouson is offline
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I had everything made and set it up on 09 900 Classic. Sold the bike after almost 3 years and 13,500 miles for $500 less than I bought it for. Posted pics of completed bike in my introduction http://www.vulcanbagger.com/forums/s...ad.php?t=28252
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My friends call me KC!!
Wichita, KS
VBA #02089

In order installed:
Audio Adaptor Kit
Mini Air Pump
After market 132db horn
Barefoot Willies "Cool Rider" Cup Holder
Garage Door Opener (ala Gadget's Website)
16" Kawasaki Windshield
Door Trim to stop Gas Tank Cover Rattle
Single Schrader Valve Setup (ala jestephens)
Non-bike stuff:
Kawasaki Banner in Garage
Previous Bikes:
75 Yamaha 175
09 Vulcan 900 Classic
Harleys:
75 Sportster XLCH
84 Sportster 1000
85 FXRT
79 Low Rider
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Old 05-29-2012, 07:04 AM   #5
dmyers   dmyers is online now
 
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You do good work
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2012 green vaquero
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Old 05-29-2012, 09:02 AM   #6
ringadingh   ringadingh is online now
 
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That looks like its on there really nice and neat.
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Old 05-29-2012, 09:04 AM   #7
rewindgy   rewindgy is offline
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Very nice! I couldn't find a fairing for a reasonable price up here! Then when I had given up, one shows up for a couple hundred dollars and I just didn't bother! Looks real good - especially in the faster color "black:!
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Old 05-30-2012, 02:12 PM   #8
thonly1   thonly1 is offline
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Good work, and a timely post. Thanks!
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Old 06-02-2012, 12:04 AM   #9
CycleDude   CycleDude is offline
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I did a Harley Batwing on my 900 a few years back. It's pictured up on Gadget's page...

http://www.gadgetjq.com/kl_fairing_adapt.htm

It was crazy easy using those handlebar windsheild mounts like the memphis shades ones, and regular old L brackets from the hardware store.


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