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Gen 3 Front Cowl removal?
Posted: Sat Oct 15, 2022 12:30 pm
by mcatrophy
Posted this elsewhere, but I know some don’t visit there, so I am trying here as well.
Can someone help me to remove my 2018's front cowl? (Guess who's broken the mirror support frame. Again.)
Yes, I've done a search, found nothing that helps me.
I have done it before, but not the right way. It was a nightmare, many impossible to get at fasteners. I did take
some pics (they start with some side panel stuff, got those off easy-peasy), but not enough detail or explanation, I can't even see how to get to some of the fasteners I got to then.
I'm sure I've seen a post somewhere that shows it.
Thanks in advance.
Re: Gen 3 Front Cowl removal?
Posted: Sat Oct 15, 2022 1:01 pm
by raYzerman
My first suggestion is to remove the large dash trim and fix the thing with Permatex epoxy (JB Weld too runny for this job).... it will be great until the next time and not be such a PITA to swap the part......... smear epoxy on both raw edges and stick together in situ... remove mirror if necessary, the cowling will hold it in place..... when that dries, smear on another layer on either side and it will hold very well....... that said......
Your photos are how it's done on all Gen3's...... that's been used by several, including myself and thank you for doing that. Side fairings have to come off, note the screws on either side at the corner where it joins the front cowl. I think one screw at the battery box if memory serves. The only screw you don't have to remove is the middle one holding the headlight, no need for your special screwdriver. That one stays. I've changed a couple, need a normal and short JIS screwdriver. 1/4" drive with universal joint and a couple of extensions will help get at the harder ones.
I'd still go for the epoxy job, it's quite good and easiest/cheapest. I broke mine 3 times with whoopsies, and when I finally broke the mirror tab off, I decided to change the stay.
Re: Gen 3 Front Cowl removal?
Posted: Sat Oct 15, 2022 4:08 pm
by mcatrophy
raYzerman wrote: ↑Sat Oct 15, 2022 1:01 pm
My first suggestion is to remove the large dash trim and fix the thing with Permatex epoxy (JB Weld too runny for this job).... it will be great until the next time and not be such a PITA to swap the part......... smear epoxy on both raw edges and stick together in situ... remove mirror if necessary, the cowling will hold it in place..... when that dries, smear on another layer on either side and it will hold very well....... that said......
Your photos are how it's done on all Gen3's...... that's been used by several, including myself and thank you for doing that. Side fairings have to come off, note the screws on either side at the corner where it joins the front cowl. I think one screw at the battery box if memory serves. The only screw you don't have to remove is the middle one holding the headlight, no need for your special screwdriver. That one stays. I've changed a couple, need a normal and short JIS screwdriver. 1/4" drive with universal joint and a couple of extensions will help get at the harder ones.
I'd still go for the epoxy job, it's quite good and easiest/cheapest. I broke mine 3 times with whoopsies, and when I finally broke the mirror tab off, I decided to change the stay.
Thanks for your reply. Yes, side fairings no problem, done those several times. I've documented those in
pics and a
pdf file, the words are by MNFJR05 (now PapaUtah?) from
this thread.
I won't try gluing it, though thanks for the suggestion. It just goes against my view on what is "right", particularly as I might have to sell it soon, very possibly through my dealer. He has treated me very well since I got my first FJR in 2006. Wouldn't want to land him with a potential warranty claim if it fails.
Oh, well, have to have another go.
Re: Gen 3 Front Cowl removal?
Posted: Sat Oct 15, 2022 4:45 pm
by LKLD
Mac, going for a ‘22? Based on your sig, you get one every 4 yrs.
Good luck with the stay, as you already know, itzabich!
Re: Gen 3 Front Cowl removal?
Posted: Sun Oct 16, 2022 4:19 am
by mcatrophy
LKLD wrote: ↑Sat Oct 15, 2022 4:45 pm
Mac, going for a ‘22? Based on your sig, you get one every 4 yrs.
Good luck with the stay, as you already know, itzabich!
The "one every four years" is more by happenstance than any policy (no, before you ask, never actually managed to write one off!)
Only the 2018 was bought "just because", that was to try to recover my fun in riding after the loss of my wife (you were amongst those good enough to respond to
my thread about that).
In any case, FJRs are unfortunately no longer available here, also I can't see me being physically able to ride for much longer. The figure "80" is really starting to tell.
Re: Gen 3 Front Cowl removal?
Posted: Sun Oct 16, 2022 7:23 am
by wheatonFJR
mcatrophy wrote: ↑Sun Oct 16, 2022 4:19 am
LKLD wrote: ↑Sat Oct 15, 2022 4:45 pm
Mac, going for a ‘22? Based on your sig, you get one every 4 yrs.
Good luck with the stay, as you already know, itzabich!
The "one every four years" is more by happenstance than any policy (no, before you ask, never actually managed to write one off!). Only the 2018 was bought "just because", that was to try to recover my fun in riding after the loss of my wife (you were amongst those good enough to respond to
my thread about that).
In any case, unfortunately FJRs are no longer available here, also I can't see me being physically able to ride for much longer. The figure "80" is really starting to tell.
Mac, if I was able to view and respond to your post over there I would have. As you are 80, I get it. I am 63 and my mom lived till she was 68. All I can say is Im no help to you, but your photos were a great help to me as I took the front fairing off...simply couldn't have done it without your photos and MNFjr's text.
That and I hope you can ride for a long time, even though we know the end is nearer than we wish.
Re: Gen 3 Front Cowl removal?
Posted: Sun Oct 16, 2022 7:27 am
by mcatrophy
Job has made some progress.
Funny(?) bit. Got the the headlight part off, looked to see how mirror stay is bolted to frame. "Ah", thinks I, "Look at the new part, easy to find where it's bolted." So, look at box with new bits in, pick out the stay, take it out of its wrappings. "B*gg*r. Wrong stay."
Between my dealer and me, we'd ordered the stay the windscreen bolts to.
Means the job will be on hold until I can get the right part. Pity, I had something planned for Saturday.
Wanted item 15, got item 8.
(Click on image for larger view)
Re: Gen 3 Front Cowl removal?
Posted: Sun Oct 16, 2022 7:39 am
by wheatonFJR
Well, that's not funny haha for sure!
Re: Gen 3 Front Cowl removal?
Posted: Wed Oct 19, 2022 10:09 am
by mcatrophy
Such a good feeling when your ratchet is switched from "undo" to "do up". Only another hundred hours or so to rebuild the bike. That's if I took enough pics.
Re: Gen 3 Front Cowl removal?
Posted: Wed Oct 19, 2022 10:55 am
by wheatonFJR
mcatrophy wrote: ↑Wed Oct 19, 2022 10:09 am
Such a good feeling when your ratchet is switched from "undo" to "do up". Only another hundred hours or so to rebuild the bike. That's if I took enough pics.
I've got faith in the guy from Derby! You got this!
Re: Gen 3 Front Cowl removal?
Posted: Wed Oct 19, 2022 11:17 am
by mcatrophy
wheatonFJR wrote: ↑Wed Oct 19, 2022 10:55 am
mcatrophy wrote: ↑Wed Oct 19, 2022 10:09 am
Such a good feeling when your ratchet is switched from "undo" to "do up". Only another hundred hours or so to rebuild the bike. That's if I took enough pics.
I've got faith in the guy from Derby! You got this!
Did take three repositionings of that 'orrible frame to get the wiring through to the front properly. At least, I think it's correct now.
(Brought to you in the middle of it happening. Or not. Still to see if the 37 connectors can do up. Hope your faith is justified.)
Re: Gen 3 Front Cowl removal?
Posted: Wed Oct 19, 2022 11:58 am
by wheatonFJR
It’s certainly easier to take things apart!
Re: Gen 3 Front Cowl removal?
Posted: Sat Oct 22, 2022 4:16 pm
by mcatrophy
Finally got together at about 7:00 this evening. I had got it together at 5:00. Tested everything I could without starting the engine (didn't want any flooding issues).
Put tools away, got kitted up to do a quick test ride. Ignition on, every thing looked normal. Pressed the starter. No reaction whatsoever. Nothing. Zilch. Nada.
A good job I was wearing my helmet, some of the choice words I used would have made the neighbours realise I am not the nice person I’d got them to believe I was.
Figured it had to be a connector, so off with panels searching for the one I'd missed. Eventually found it (in front of the battery).
Had to put all the panels back on again, lost a pop-rivet and a screw. But it's together, and it runs.
Late test run: no problems.
Model of the story? Never put your tools away until you have done a full and complete check on your work, always leads to needing them out again.
Was going to go to sister-in-law's on it tomorrow for a family gathering, but heavy rain and thunderstorms forecast most of the day. Whilst I don't mind riding in the rain, it's not the fun run I was hoping for. Looks like car.
Re: Gen 3 Front Cowl removal?
Posted: Sat Oct 22, 2022 6:07 pm
by raYzerman
It's a fun job to say the least....... glad to see you got the puzzle pieces together.
