Installing the Windbender Electric Operator GL1800
These instructions are written assuming that a Windbender windshield is already installed on the motorcycle and the front trim hasn’t yet been re-installed. If the windshield isn’t already installed, please refer to the instructions on windshield installation that came with the windshield.
Locating the cable bracket
Remove the upper half of the windshield. After trimming the pattern with scissors, locate the pattern on the lower base of the windshield and mark the center of the holes with an ice pick or some other suitable tool.
Mounting the cable bracket
Release the windshield locking levers and raise the windshield to full extension. After drilling two ¼” holes, install the cable bracket with two screws from the inside of the windshield as shown. Once the bracket and snap caps over the screws are installed, lower the windshield base to its original position.
Modifying cable access
Using a file, powered rotary file, or other suitable tool, open up a semicircle hole adjacent to the existing opening next to the mounting screw shown.
Right faring pocket removal
Unlock the right faring pocket. Remove the four fasteners accordingly and lift the pocket out of the faring. Disconnect the release cable. Transfer the latch assembly from the original pocket to the modified pocket provided.
(Remove the trim clips by pushing the center pin in.)
Cable insertion
Remove the geared rack and the jam nut on the push-pull cable. Insert the cable, rack end first, into the hole created in the faring. The cable will slide between the inner headlight assembly and the air intake duct. Reach into the faring and pull the cable through
Cable reinforcement
To avoid paint damage around the pocket area, we recommend laying a towel down for protection. After dipping the clear plastic tube in hot water (to enable getting it into position), slip it on to the cable housing as shown and install the two clamps firmly. This reinforces the cable conduit from failure due to the effect of heat from the GL1800 radiator. Do not use a lubricant other than water .
Motor-cable connection
Thread the jam nut all of the way onto the cable housing. Thread the motor assembly all of the way onto the cable housing. Push the cable extension while pulling the inner cable all of the way into the motor assembly. Lightly pull the inner cable out of the rack groove for access, thread the rack onto the inner cable fitting. Apply a light film of multipurpose grease to all four sides of the rack (including the gear teeth) and press into place approximately mid travel.
Motor installation step 1
Install the rack cover with the five screws provided. It should fit flush when in the correct location. Rotate the motor assembly over so that the rack cover is in the down position and the motor wires are positioned for access.
Motor installation step 2
Pulling the cable assembly with the right hand, while guiding the motor assembly with the left, guide the motor assembly into the faring and all of the way to the front as shown. To check if the motor is in location, set the modified faring pocket in place. If the pocket sets in correctly, the motor is far enough forward.
Routing the cable
Route the cable in a looping manner to the cable bracket. The path needs to cross under the windshield holder plate. Insert the cable housing into the bracket (the lock washer should be under the top nut) and tighten. In this case, the rubber pad located just left of center, under the windshield holder plate, may need to be removed for cable routing. Attach the windshield holder plate in position. Making sure the windshield adjustment levers are released, move the windshield base up and down to ensure full travel with the OEM manual adjustment.
DO NOT BEND THE CABLE TIGHTER THAN A 4” RADIUS.
Installing the switch
Slide the left handgrip back allowing a half inch between the handgrip and the control pod. Install the switch housing next to the control pod with the switch below the handlebar and in easy reach of the left thumb. Slide the handgrip up tight to the switch housing. Route the wires to the motor location by using the same open area in the faring, provided for the factory wiring harnesses.
Installing the power supply wires
Remove the seat and the battery cover. Attach the black wire to the positive terminal and the white wire to the negative terminal on the battery. Route the wires to the motor location in the same manner as the switch wires. Re-install the seat and side cover.
Installing the relays
Plug the drive motor, switch harness, and power supply into the corresponding plug-ins on the relay assembly. Operate the switch to test proper function of the push pull cable. At the windshield end of the cable, check for full travel while actuating the switch. Travel limits are acceptable from 2 7/8” – 3 1/8”.
Final cable adjustment
The critical adjustment requires a minimum of a minor gap (paper thickness) between the top nut on the cable housing and the fitting on the shaft, in the full down position. This adjustment is accomplished by the depth of the cable housing into the motor assembly and the location of the jam nut that fits into the cable bracket. After verification or correction of clearance, insert the relay assembly and wiring into the faring along the left side of the motor assembly while positioning the components so that the modified faring pocket can be installed. Connect the release cable to the faring pocket and install. Some 2001 models may require drilling the left mounting holes of the pocket to accept the trim clips. Later models use screws at these two locations.
Locating the ball-stud
Re-install the windshield onto the lower base. Adjust the windshield to the lowest position and lock into place with the two quick release pins for manual adjustment. With the operating switch, retract the cable extension on the electric operator all of the way down. From the front of the motorcycle, looking through the windshield, mark the center location of the socket on the cable extension so that a ¼” hole can be drilled through the windshield to accommodate the ball stud. It would be a good idea to double check center by measuring from the two slide brackets
Mounting the ball-stud
Remove the upper windshield and drill a ¼” hole at the location marked. Install the ball stud using a nylon washer on each side of the windshield with the ball end on the inside. Using the electric switch, extend the cable extension all of the way out. Install the windshield and connect the cable extension to the ball stud. Warning, do not re-install the quick release pins
Cycle the windshield up and down a few times to ensure proper movement.
Re-install any final items left to be put on.
Although removal of the windshield can be accomplished at any height, it should be done as a normal procedure at full extension, to allow for as much flex as possible between the cable extension and the ball stud.
The two quick release pins can be carried in a faring pocket in case of emergency. In the event of an unforeseen failure, the cable extension can be released from the windshield and the manual adjustment can be used.
IMPORTANT
Normal windshield movement is possible at all normal riding speeds. However, physically, impeding normal travel of the windshield while activating the motor drive can cause motor or cable failure.
Due to the high heat in the motor location, a locked up condition can occur with the electric actuator after the bike has cooled down with the windshield in the full down position. This is normal and can be avoided by raising the windshield slightly before shutting down. If this does occur, bringing the bike to full operating temperature, or heating up the motor drive with a hair dryer will allow the motor transmission to release.