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Old Aug 14th 2012, 02:10 AM   #1
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Watch out for front cowl removal!

So I took my front cowl off today, I am EXTREMELY careful when removing parts in order, meticulousness, finesse, etc. But these tabs on the outside where it mounts to the fairing stay on the sides, are an absolute design flaw in my opinion. Today I took it off, attached the Puig windscreen and sure enought the entire tab was separated from the inside of the cowl.

First you need this - Amazon.com: Permatex 84115 PermaPoxy 5 minute Plastic Weld, 0.84 oz.: Automotive

Get some 400 Grit sand paper.

Make sure it is mixed 50/50, it takes 15-20 minutes to set, I was in high heat outside so it took about 5 minutes less to start curing.

Also make sure that you make sure it is on raw plastic, thats what the 400Grit Sandpaper is for, I would give pics but it didn't cross my mind while doing it.

Good luck!
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Old Aug 14th 2012, 02:28 AM   #2
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Wow, sorry to hear you had issues with that.

Any indication of location you can make on a pic would be appreciated, as I need to fit my DDA soon, which I believe requires the front cowl to be removed.
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Old Aug 14th 2012, 02:42 AM   #3
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After you remove the ignition cover, remove the black side cowl covers, the outermost bolts (8mm) that is the tab I am talking about.
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Old Aug 14th 2012, 04:18 AM   #4
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Originally Posted by b1six View Post
But these tabs on the outside where it mounts to the fairing stay on the sides, are an absolute design flaw in my opinion.
My dealer found this out during the first service. They broke one of the tabs on the front of the side fairing. They replaced it with a new one.
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Old Aug 14th 2012, 11:04 AM   #5
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It's tough to pull the front fairing, I did it very slowly and gently so no tabs broken, but sweated the whole time Also, an error in the manual, their are two plastic mounting stays (they have an inner sleeve that when pushed into the hole, the inner sleeve pushed down it locks into place, you remove by sticking a flat blade screwdriver under the inner (spike?) part and lifting, it's hard to explain, the two are located on each side in the radiator area just below the front fairing.
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Old Aug 14th 2012, 01:11 PM   #6
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Originally Posted by zvez View Post
It's tough to pull the front fairing, I did it very slowly and gently so no tabs broken, but sweated the whole time Also, an error in the manual, their are two plastic mounting stays (they have an inner sleeve that when pushed into the hole, the inner sleeve pushed down it locks into place, you remove by sticking a flat blade screwdriver under the inner (spike?) part and lifting, it's hard to explain, the two are located on each side in the radiator area just below the front fairing.
Pics?
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Old Aug 14th 2012, 01:12 PM   #7
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Originally Posted by SoonerNation View Post
My dealer found this out during the first service. They broke one of the tabs on the front of the side fairing. They replaced it with a new one.
After fixing them, i will never have the issue again.
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Old Aug 14th 2012, 02:47 PM   #8
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sorry, no pics but I've attached a pic from the manual. It only indicates two of the plastic fasteners (one on each side) but if you look closely the second one is visible just behind the two marked "6"
As said, these are two part plastic fasteners, they're removed by slipping a flat blade screwdriver under the head of the inner part, this opens the fitting and it pops right out.


Originally Posted by b1six View Post
Pics?
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Watch out for front cowl removal!-fairing.jpg  
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Old Aug 14th 2012, 03:22 PM   #9
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Yeah I did something similar, I used loctite plastic epoxy, no issues since.
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Old Aug 14th 2012, 06:28 PM   #10
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Originally Posted by TransNone13 View Post
Yeah I did something similar, I used loctite plastic epoxy, no issues since.
Link?
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