AIRMASTER DELUXE FAIRING 1335 PARTS INCLUDED 1 Airmaster Fairing 1 Dragon Wing Spacer kit 1 Light Bar Relocation Hardware Kit 2 1/2" Spacers 2 1" Spacers 6 5/16"-24 x 1" Button Head Cap Screw, Chrome 4 5/16"-24 x 1-1/2" Button Head Cap Screw, Chrome 4 5/16" Flat Washer, Chrome 2 5/16" x 1/8" Thick Washer, Zinc 2 #10-24 x 1/2" Button Head Cap Screw, Chrome 2 #10-24 Nylon Locking Nut, Zinc 4 5/16"-24 Nylon Locking Nut, Zinc 2 Relocation Brackets, Chrome 1 Rubber GPS Mounting Block with Support Bracket 1 Weather Cover for Stereo 2 Cigarette Lighter / Power Points 1 Sony DSX-S100 Manual and Accessories 1 Installation Instructions Please read and understand entire instructions before starting installation. THANK YOU FOR CHOOSING KϋRYAKYN! CUSTOMER SERVICE 877.370.3604 (toll free) QUESTIONS techsupport@kuryakyn.com or call 715.247.2983 LIMITED WARRANTY Küryakyn warrants that any Küryakyn products sold hereunder, shall be free of defects in materials and workmanship for a period of one (1) year from the date of purchase by the consumer excepting the following provisions: Küryakyn shall have no obligation in the event the customer is unable to provide a receipt showing the date the customer purchased the product(s). The product must be properly installed, maintained and operated under normal conditions. Küryakyn makes no warranty, expressed or implied, with respect to any gold plated products. Küryakyn shall not be liable for any consequential and incidental damages, including labor and paint, resulting from failure of a Küryakyn product, failure to deliver, delay in delivery, delivery in nonconforming condition, or for any breech of contract or duty between Küryakyn and a customer. IN ORDER TO PROTECT YOU AND OTHERS FROM POSSIBLE INJURY AND/OR PROPERTY DAMAGE OR LOSS, PLEASE PAY CLOSE ATTENTION TO ALL INSTRUCTIONS, WARNINGS, CAUTIONS AND ATTENTION NOTES REGARDING THE USE AND CARE OF THIS PRODUCT. WARNING! THIS INDICATION ALERTS YOU TO THE FACT THAT IGNORING THE CONTENTS DESCRIBED HEREIN CAN RESULT IN POTENTIAL DEATH OR SERIOUS INJURY. ATTENTION! This indication alerts you to the fact that ignoring the contents described herein may negatively affect product performance and functionality. This indication alerts you to the fact that ignoring the contents described herein can result in potential injury or material damage. TOOLS SUGGESTED Set of Hex Wrenches, Set of Combination Wrenches STRICTLY OBSERVE THE FOLLOWING GUIDELINES IN ORDER TO USE THE PRODUCT PROPERLY AND AVOID POTENTIALLY DANGEROUS ACCIDENTS. STEP 1 Read and understand all steps in the instructions before starting the installation. Park the motorcycle on a hard, level surface and turn off the ignition. Küryakyn products are often intended for use in specific applications. Küryakyn makes no warranty if a Küryakyn product is used in applications other than intended. Küryakyn electrical products are warranted for one (1) year from the date of purchase by the consumer. L.E.D. S contained in components of Küryakyn products will be warranted for defects in materials and workmanship for 3 years from the date of purchase where as all other components shall be warranted for one(1) year. This includes, but is not limited to; control modules, wiring, chrome & other components. Küryakyn makes no warranty of any kind in regard to other manufacturer¹s products distributed by Küryakyn. Küryakyn will pass on all warranties made by the manufacturer and where possible, will expedite the claim on behalf of the customer, but ultimately, responsibility for disposition of the warranty claim lies with the manufacturer. ABOUT OUR CATALOG For purchasing Küryakyn products, you can receive a complete catalog free of charge. Send the Proof-of-Purchase below with your address to: Küryakyn, P.O. Box 339, Somerset, WI 54025. Please indicate either Accessories Catalog for Harley-Davidson or GL & Metric Cruisers. Be sure to ask your local dealer about other Küryakyn products, the motorcycle parts and accessories designed for riders by riders. 2005 Küryakyn USA All Rights reserved. NOTE: May be installed on Fat Boy models, however the customer is responsible for supplying mounting hardware and relocating handlebar mounted turn signals. 1335-22MC-0212
WARNING! IF INSTALLING THIS PRODUCT FOR ANOTHER PARTY, PLEASE MAKE SURE THEY RECEIVE THIS COPY OF THE INSTRUCTIONS SO THEY ARE AWARE OF THESE IMPORTANT WARNINGS. WARNING! YOU WILL BE WORKING AROUND THE ENGINE AND EXHAUST SYSTEM DURING. ENSURE THAT THE ENGINE AND EXHAUST SYSTEM HAVE FULLY COOLED TO PREVENT INJURY. Avoid damage to the motorcycle. Protect painted surfaces with a soft cloth or blanket. ATTENTION! A factory service manual may be helpful in performing this installation. Do not attempt to perform this installation if you are not confident in your ability to complete all of the steps in the procedure; consult a trained technician. NOTE: To ensure proper clearance between the Airmaster Fairing and the passing lamps, Kuryakyn recommends aligning and adjusting them before installation of the fairing. ALIGNMENT AND ADJUSMENT OF PASSING LAMPS STEP 2 Park the motorcycle on level ground 25 feet from a wall or screen. With the rider seated on the motorcycle & the wheel pointed straight, measure the centerline position of the headlamp from the ground. On the wall, measure the same distance up from the ground in a straight line and mark the height with a piece of tape. STEP 3 Turn the headlight on to the high beam position and check the alignment of the headlight. If needed, loosen and adjust the headlight to align with the markings made in Step 2. STEP 4 Locate the left and right side passing lamp centerlines by measuring the distance from the headlight centerline out to each of the passing lamps on the motorcycle. Mark the distance measured out on the wall. STEP 5 Cover the headlamp beam and adjust the passing lamps so that the high intensity zone of both the left and right passing lamps shine below and to the right of the passing light locations made on the wall. NOTE: It may be helpful to adjust one light at a time, covering the light that is not being adjusted. STEP 6 After alignment, tighten the passing lamps in reverse order they were loosened in Step 3 of the disassembly procedure above. NOTE: Be sure to minimize passing lamp movement while tightening. If excessive movement permitted, passing lamp aim will be effected. 2
OF AIRMASTER FAIRING FIG 1 STEP 7 Place a fender cover or protective material over the front fender to prevent damaging the fender. 5/16 X 1/8 THICK WASHER FAIRING BRACKET STEP 8 Loosen Passing Lamps. On the Deluxe, start by removing the bezel and light from the housing then loosening the nut on the inside. On the Heritage, remove the front turn signals to gain access to the nut. STEP 9 STEP 10 STEP 11 Remove the four screws that attach the light bar to the front forks and rotate the light bar forward so that it rests on the front fender. Loosely install the four screws, chrome flat washers and spacers from the hardware kit into the front forks. Place the 1-1/2 screws with 5/16" flat washers and the 1 spacers into the top holes. Then install 1 screw with 5/16" flat washer and the 1/2 spacer into the bottom holes. Rotate the light bar back so the bottom rests on the fender. Center the top of the light bar on the fork tubes. NOTE: Positioning the light bar in this manner will greatly ease mounting later on. ATTENTION! Assistance is recommended in securing the fairing during the installation process. OEM LIGHT BRACKET 1 SPACER FIG 2 1/2 SPACER RELOCATION BRACKET 1 SPACER FAIRING BRACKET 5/16-24 X 1-1/2 #10-24 X 1/2 5/16-24 X 1-1/2 STEP 12 Set the fairing in place with the cutouts of the fairing bracket on the screws between the chrome flat washers and the spacers. STEP 13 Line up the top holes from light bar with the top-front holes on the fairing bracket. Insert the 5/16" x 1/8" thick washer between the fairing brackets and the light bar FIG 1 (except Deluxe; FIG 2). Insert the screws through the holes and loosely secure the nuts to the screws. RELOCATION BRACKET STEP 14 Remove the bottom bolts from the fairing bracket, be sure to hold the short spacers in place. All models (except the Deluxe; FIG 2) bolt the relocation brackets to the inside of the fairing bracket, between the short spacer and fairing bracket. Loosely reinstall the bolts. FIG 1 For the Deluxe, bolt the relocation bracket to the outside of the fairing bracket FIG 2. OEM LIGHT BRACKET 1/2 SPACER STEP 15 Loosely install the two 10-24 screws and nuts through the fairing bracket and relocation brackets. 5/16 X 1/8 THICK WASHER #10-24 X 1/2 STEP 16 Align the slotted holes from the relocation brackets with the holes on the bottom of the light bar. FIG 1 For the Deluxe (FIG 2), place the 5/16-1/8 thick washers between the relocation brackets and the light bar. Slide the screws through the holes and loosely install the nuts. NOTE: Before tightening the hardware, check for ample clearance between the fairing and all surrounding components. (I.E. Handlebars, Risers, Controls, Passing Lamps, etc.) WARNING! ENSURE THAT THE FAIRING AND MOUNTING HARDWARE DO NOT INTERFERE WITH ANY CABLES, WIRING OR WITH THE FUEL TANK ON THE MOTORCYCLE WHEN THE FORK IS TURNED LOCK TO LOCK. STEP 17 Tighten the four screws that secure the fairing to the bike. Adjust the light bar through the slotted mounting holes and tighten the six remaining screws. 3
ATTENTION! It is the installer s responsibility to ensure that all of the fasteners (including pre-assembled) are tightened before operation of the motorcycle. Küryakyn will not issue a warranty on components lost due to improper installation. Periodic maintenance may be required. WARNING! SET ALL RADIO CONTROLS WHILE STOPPED. DO NOT ATTEMPT TO ADJUST YOUR RADIO CONTROLS WHILE OPERATING THE MOTORCYCLE. Ensure that the installation of this product does not interfere with the proper operation of the motorcycle before riding. WARNING! ANY MODIFICATION TO THE MOTORCYCLE, LIKE ADDING A FAIRING OR WINDSHIELD, WILL HAVE AN EFFECT ON THE MOTORCYCLE S SLOW AND HIGH SPEED HANDLING. FAMILIARIZE YOURSELF WITH THE ADDED WEIGHT AND DIFFERENT LINE OF SIGHT BEFORE RIDING THE MOTORCYCLE FOR THE FIRST TIME. THE ADDED WIND PROTECTION FROM THE FAIRING MAY AFFECT YOUR JUDGMENT OF SPEED. THE EFFECT OF CROSSWINDS OR OF THE WIND CREATED FROM PASSING LARGE VEHICLES MAY AFFECT THE HANDLING OF THE MOTORCYCLE. BE AWARE OF THESE DIFFERENCES AND OTHERS THAT MAY ARISE. FAILURE TO COMPENSATE FOR WITH THESE DIFFERENCES MAY CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. CONNECTING POWER WIRES STEP 18 STEP 19 STEP 20 Remove the seat to gain access the battery. Remove the instrument panel. Plug the harness from the fairing to the wiring harness, route the wiring harness back to the battery. Take the wiring harness ends and connect positive and negative fork terminals to the positive and negative mounts on the battery. NOTE: The positive wire has an in-line fuse. STEP 21 Connect the wire labeled "switch power" to keyed 12V power. This allows the stereo to power up only when the key is in the "On" position. NOTE: Connecting this wire to constant power will result in battery drain. STEP 22 Tuck the wiring harness away and re-mount the instrument panel ATTENTION! Secure all wiring away from any moving parts, pinch points or extreme heat. Küryakyn WILL NOT issue a warranty on any electrical component that fails due to pinched, crimped, broken, abraded, melted or frayed wires. STEP 23 Secure any excess wiring out of the way and replace the seat. WARNING! AFTER INSTALLING THE SEAT, PULL UP ON IT TO ENSURE IT IS LOCKED INTO PLACE. A LOOSE SEAT CAN SHIFT AND CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. 4
FAIRING FEATURES The Airmaster fairing has many features and options, making it very user friendly. Inside the box you will find a non-slide rubber mat, a cigarette lighter/power point, keys, stereo instructions and the stereo "weather" cover. Also, a spacer kit that will be included that will be needed if you wish to install the Küryakyn Dragon Wings sold separately. (Küryakyn P/N 1117 or 1108) NOTE: The Dragon Wing spacer kit is needed when installing the Küryakyn Dragon wings; they allow smooth operation of the Dragon Wings. Place the spacers behind the center and top Dragon Wing mounting hole locations. Refer to included Sony manual for information or receiver operation and use. The cigarette lighter/power point is for use for any type of charging you may need (i.e. cell phone ect ) You may also use it for the lighter function. The fairing also has an alternative cigarette lighter/power point. It is located to the lower left hand side just below the handlebars. The GPS rubber block mount is an option that we provided to make the installation of a GPS easier for the customers. On the inside of the fairing storage compartment door, you will find four preformed holes that line up with the rubber block mount. Using a drill, you can drill the four holes on the inside of the fairing storage compartment door. Once the holes are drilled, you will be able to take the rubber block mount and place it between the GPS and the fairing storage compartment door to help absorb some of the vibration from the bike as well as allowing the GPS to mount flat on the door. The steel plate must be used inside the door to provide additional support. The Stereo "weather" cover is needed when you wish to wash the bike or for use when you store the bike. Place the tabs on the right side of the cover into the two slots on the right side of the stereo opening. Gently snap the left side into place and make sure that it is securely in place. ATTENTION! When washing your bike, try to avoid excessive water usage around the stereo and speaker areas. Too much water contact could potentially damage the components in this fairing. CARE and MAINTENANCE Clean only with warm water and a mild, non-abrasive soap. Some cleaning products contain harsh chemicals that can severely damage product and void warranty. Do not clean Lexan polycarbonate in hot sun or high temperature. Powdered, abrasive or alkaline cleanser will damage the windshield and f airing. Never scrape the windshield or fairing with a razor blade or other sharp instrument. Do not use benzene, paint thinner, gasoline or any other type of harsh cleaner on the windshield. Do not use ammonia based solvents or petroleum distillates. Doing so will damage the windshield and fairing surface. Do not use harsh chemicals including rain sheeting products on motorcycle windshields or fairing. They can cause a dulling or hazing. To obtain a proper high-end polish, please use a quality protector and polish such as Plexus or Novus brand cleaners on the windshield and an automotive quality wax or polish on painted fairing. NOTE: Sunlight reflections off the inside curvature of the windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windshield to avoid reflections. Ride On! 5