2015 front cowling/headlight rattle fix - Kawasaki Versys Forum
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post #1 of 5 (permalink) Old 03-24-2016, 05:43 PM Thread Starter
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2015 front cowling/headlight rattle fix

My 2015 650 developed a nasty rattle after 200 miles just below 2000 RPMs. I took it back to the dealership, and the mechanic grabbed an old piece of styrofoam that was on the floor and wedged it between the headlight assembly and the front cowling, and said, "fixed." I'm not planning on going back. I removed the headlight and found inadequate dampening. My rattle seemed to be coming from the areas circled in red in 1st photo. After trying various additions of foam around the plastic cowling, I ended up removing the 6 pads from the cowling, and wrapped the headlight assembly instead with 1/2 inch neoprene tape, shown in next photos. Feels super solid now, and rattle gone.
Attached Images
File Type: jpg Front cowling.jpg (58.9 KB, 275 views)
File Type: jpg IMG_0372.jpg (56.5 KB, 254 views)
File Type: jpg IMG_0373.jpg (53.8 KB, 253 views)
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Last edited by IAMRA; 03-25-2016 at 12:41 AM.
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post #2 of 5 (permalink) Old 05-09-2016, 10:05 PM
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How long did it take you to remove the front cowling and headlight assembly?

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post #3 of 5 (permalink) Old 05-09-2016, 10:49 PM Thread Starter
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Only minutes. Really very easy.
Remove left and right fairings (4 bolts each)
Remove upper meter cover (2 bolts, 2 rivet pins)
Remove front cowling (4 bolts, 4 rivet pins)
Disconnect headlight and city light wires, and pull the front cowling forward, out of the grommets.
Separate headlight assembly from front cowling (5 screws)
I suspect more Gen 3s will start to have this problem.
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post #4 of 5 (permalink) Old 05-09-2016, 10:59 PM
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One problem,

Seems mighty tempting to swap some LEDs in there while everything's off the bike...

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post #5 of 5 (permalink) Old 05-09-2016, 11:49 PM Thread Starter
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Yes, I know this problem well.
Have you seen my thread on LEDs
http://www.kawasakiversys.com/forums...ml#post1135378
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