ZN1300 Voyager Fairing Repair

		ZN1300 Fairing Repair

Last Update 8/22/08

This page shows how I made some repairs on my Voyager fairing. When I bought this bike it had been wrecked and the fairing was pretty busted up, but all these fairings tend to get stress cracks in them from age anyway. Another issue is all the weight carried inside from the combination AM/FM Radio, Cassette, CB and Intercom system installed inside the fairing. If you pull all of those components out, that's probably about 20 - 25 lbs worth of electronics! Every time you hit a bump in the road this stuff is shaking around in the fairing and just tears the plastic shell up in short order.

The purple beast! You either love it or hate it! It's amazing the comments I get about it both ways.

The front bottom was busted pretty good so I cut a piece of thin sheet-metal and bought some epoxy from the local hardware and fit it back together. Lots of work just to strip all the parts out of the fairing. I would suggest you take notes when you're pulling these wires apart or even take some pictures. Though the electrical plugs are all color coded, the radio wiring can get very confusing and those can easily be plugged in the wrong spot.

I put globs of this epoxy in a few spots that had cracks.

Right side

Left side

There were some stress cracks that they covered with fiberglass when I had it prepped for painting.

Body shop took my headlight bucket out to do fiberglass repair around the nose and they cut the pop rivets that held the metal headlight mounting piece in place. Pulling that apart was unnecessary.

So it doesn't look perfect on the inside, but if it doesn't crack again...

One issue was getting the dash to go back into place properly. They glassed over the mounting holes in the fairing where the bottom side of this assembly mounts up. This pushed the whole dash up and I had to do some grinding to the glass they added to drop it back down some so I could get it to fit back together.

On reassembly, I left all the radio components out and covered the holes in the front with a smoked plastic cover that a local glass shop cut for me and installed for only $10!

Here's the 2 different style right side 'gloveboxes' that were used depending on whether your Kawasaki was ordered with the CB Radio option. They put the CB tuner under the glovebox so they made a shorter box for those bikes.

NOTE: On these newer browsers I've noticed that they don't always display my large images in full size when you open an image from the thumbnails. Once you click the thumbnail and open the larger image, if you 'mouse over' the image you should see a " + " symbol or some other indicator like a box with arrows usually on the bottom right edge of the image. If you click on the indicator, then the image will expand to it's full size which displays full screen on computers that use a 800 x 600 resolution setting for the monitor. If you click the indicator again it will go back to the smaller image. Some people use a resolution setting of 1024 x 768 or higher on their monitors and for those users the images will appear smaller than full screen in size. You can change your monitor settings easily enough if you desire. Also, the indicator I've noticed is slow to appear even after the image appears to of completely loaded. The indicator in Netscape seems to be a lot faster to display than the one in Internet Explorer.

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