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Maier Sport Cafe Style Fairing Installation
As sent to me by Bob Jones of Merriam Cycle in case anyone ever needs it.
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The Maier cafe fairings work well once installed, but they are a
little trouble even with instructions. The best thing to do is to hold it up to the headlight, so that it is equally spaced around it. Use a scribe to make impressions and scratches for hole locations. Check out the space on each side where the fork shaped brackets will attach to the head light holding bolts. You then set the fairing aside and use a vice to hold the brackets while you bend them. When you finish bending them they should
be some S or Z shape only stretch that. They fork into the headlight bolt under a large flat washer then angle out to the fairing, then bend so its flat against the inner wall of the fairing. Any number of configurations will work to position them equally on each side. once you have these shapes, install the brackets to the headlight bolts on both sides and tighten. Now, again hold the fairing up to it's desired position. Use the scribe or all to line up where the hole will be vertically and horizontally. When you determine that point. Put the point of the scribe right where the hole center will be on one side and twist while pushing until you have an indention to drill. Take the fairing down and drill that
hole. Locate or get some allen bolts about an inch long with a 1" dia. flat washer for each outside and a self locking nut for the bracket side. Bolt the side up that you drilled and then locate the other side hole while the first bolt is holding it in place for center and repeat the drilling for that side. Now bolt the fairing in place with the headlight holding brackets. Use 6mm allens you can get them at Ace hardware stores in metric. Open up the handlebar clamps with the rubber gaskets and slip them over the bars right about the bend upward. Pinch them together with pliers and put
the threaded L strut through so that it is at the bottom side of the bar and the L reaches forward and lays next to the inside wall of the fairing pointing up. One 19mm lock washer and nut goes on each side of the handle bar clamps. Just leave them snug, but not tight, so you can adjust the whole thing once it's all together. Disassemble the rear side holding bolts from their clamps. The Steel flat washer goes on the outside of the fairing. The rubber goes between the fairing and bracket. Pull the clamp
off and spread it open as before, then slide it down on the end of the L bracket upright. With the L bracket positioned from the handlebar to the fairing at a slight downward angle until it's upright end lets you slide the clamp down on it until it's about half way from top to bottom and in from the back edge of the fairing and inch or two. Eyeball the spot as before and make a mark with the scribe for the hole center. You can drill it in place by just moving the brackets back enough to clear the bit. Find
bits just big enough to allow the screws and bolts to slide through without binding up. Once this hole is drilled assemble this side mount bracket loosely, but enough so that everything stays in place, while you checkout the overall alignment and appearance of the fairing. Once you're satisfied it all looks as it should. Assemble the last bracket to match the other side and drill it. Mount it the same and tighten all bolts when final alignment is made. As you tighten the big handlebar nuts, do one turn each side back and forth on each nut because by tightening one all the way it will move and distort the fairing away from your desired position. Put the windshield on last. Unroll the foam rubber tape and put it on the margin for the window mount. Start at one side and finish at the other. Place the windshield on the fairing and put the front center screw in first. Rubber washers go on the outside. Punch through the foam with the scribe to make
each hole. Put the first one in and a flat steel flat washer on the inside followed by a black nut. Work around one side two three then go the other way until you finish. Tighten with a phillips, but hod the nuts with fingers only. don't over tighten or you'll crack the windshield (they're pricey). It's not in any instructions, but I usually eyeball where the headlight adjust screw is and drill a hole in the front off center to align with it, so there is access with a screwdriver for adjustment up and down. Otherwise it may be impossible to adjust it with the fairing in place on some models. That's how you do it, I didn't say it was easy. I mount sport
bike mirrors on the fairing too and make reinforcement plates to support them, then use another complete handlebar mount kit for them next to the original. This keeps them clear at high speed.
As sent to me by Bob Jones of Merriam Cycle in case anyone ever needs it.
--------------------------------------------------------------------
The Maier cafe fairings work well once installed, but they are a
little trouble even with instructions. The best thing to do is to hold it up to the headlight, so that it is equally spaced around it. Use a scribe to make impressions and scratches for hole locations. Check out the space on each side where the fork shaped brackets will attach to the head light holding bolts. You then set the fairing aside and use a vice to hold the brackets while you bend them. When you finish bending them they should
be some S or Z shape only stretch that. They fork into the headlight bolt under a large flat washer then angle out to the fairing, then bend so its flat against the inner wall of the fairing. Any number of configurations will work to position them equally on each side. once you have these shapes, install the brackets to the headlight bolts on both sides and tighten. Now, again hold the fairing up to it's desired position. Use the scribe or all to line up where the hole will be vertically and horizontally. When you determine that point. Put the point of the scribe right where the hole center will be on one side and twist while pushing until you have an indention to drill. Take the fairing down and drill that
hole. Locate or get some allen bolts about an inch long with a 1" dia. flat washer for each outside and a self locking nut for the bracket side. Bolt the side up that you drilled and then locate the other side hole while the first bolt is holding it in place for center and repeat the drilling for that side. Now bolt the fairing in place with the headlight holding brackets. Use 6mm allens you can get them at Ace hardware stores in metric. Open up the handlebar clamps with the rubber gaskets and slip them over the bars right about the bend upward. Pinch them together with pliers and put
the threaded L strut through so that it is at the bottom side of the bar and the L reaches forward and lays next to the inside wall of the fairing pointing up. One 19mm lock washer and nut goes on each side of the handle bar clamps. Just leave them snug, but not tight, so you can adjust the whole thing once it's all together. Disassemble the rear side holding bolts from their clamps. The Steel flat washer goes on the outside of the fairing. The rubber goes between the fairing and bracket. Pull the clamp
off and spread it open as before, then slide it down on the end of the L bracket upright. With the L bracket positioned from the handlebar to the fairing at a slight downward angle until it's upright end lets you slide the clamp down on it until it's about half way from top to bottom and in from the back edge of the fairing and inch or two. Eyeball the spot as before and make a mark with the scribe for the hole center. You can drill it in place by just moving the brackets back enough to clear the bit. Find
bits just big enough to allow the screws and bolts to slide through without binding up. Once this hole is drilled assemble this side mount bracket loosely, but enough so that everything stays in place, while you checkout the overall alignment and appearance of the fairing. Once you're satisfied it all looks as it should. Assemble the last bracket to match the other side and drill it. Mount it the same and tighten all bolts when final alignment is made. As you tighten the big handlebar nuts, do one turn each side back and forth on each nut because by tightening one all the way it will move and distort the fairing away from your desired position. Put the windshield on last. Unroll the foam rubber tape and put it on the margin for the window mount. Start at one side and finish at the other. Place the windshield on the fairing and put the front center screw in first. Rubber washers go on the outside. Punch through the foam with the scribe to make
each hole. Put the first one in and a flat steel flat washer on the inside followed by a black nut. Work around one side two three then go the other way until you finish. Tighten with a phillips, but hod the nuts with fingers only. don't over tighten or you'll crack the windshield (they're pricey). It's not in any instructions, but I usually eyeball where the headlight adjust screw is and drill a hole in the front off center to align with it, so there is access with a screwdriver for adjustment up and down. Otherwise it may be impossible to adjust it with the fairing in place on some models. That's how you do it, I didn't say it was easy. I mount sport
bike mirrors on the fairing too and make reinforcement plates to support them, then use another complete handlebar mount kit for them next to the original. This keeps them clear at high speed.