cowling crack - Kawasaki Versys Forum
 
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post #1 of 10 (permalink) Old 06-06-2012, 11:01 AM Thread Starter
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cowling crack

The right upper cowling on my '09 developed a small crack on the weekend and now the crack has traveled about 8" so a whole chunk is ready to come off. I did a search and didn't find anything on cowling cracks so this must not be a common problem.

I had taken that cowling off and put back on just before so maybe over tightened bolts although the crack did not start at a bolt. How tight should those bolts be?

Thoughts? Comments?

Thanks
Brian
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post #2 of 10 (permalink) Old 06-06-2012, 12:49 PM
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My '08 developed cracks (starting at the bolts on top) within the first year I had her. Luckily, the cracks didn't expand far (maybe an inch). Since then I have replaced both cowlings (I had scratches on both from dropping the bike on a sandy/rocky beach) and the new cowlings have been fine for the past few years.

As to how much the bolts should be tightened? I wish I had a good answer.....just enough, but not too much is how I do it now.
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post #3 of 10 (permalink) Old 06-06-2012, 03:09 PM
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I've had success repairing body work on other bikes, fortunately haven't needed to repair my '09.
I used fiberglass tape and ABS/PVC glue, and made the repair on the back side of the panel. Multiple applications of the glue is key. The front still showed a hairline crack, but it didn't spread and the panel was useable. You might give it a try.
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post #4 of 10 (permalink) Old 06-06-2012, 03:32 PM Thread Starter
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I've had success repairing body work on other bikes, fortunately haven't needed to repair my '09.
I used fiberglass tape and ABS/PVC glue, and made the repair on the back side of the panel. Multiple applications of the glue is key. The front still showed a hairline crack, but it didn't spread and the panel was useable. You might give it a try.
Thanks for the tips...I might try it. Are the panels made of ABS? Would that yellow glue that you use to glue ABS plumbing pipe work? I have some of that. And I also have PVC cement for electrical conduit.

I ordered a new panel but would still like to fix the old one and have it as a spare. Also would like to know what caused it so the same thing doesn't happen to the new panel. I am thinking to use loctite on the panel screws and then only tighten them down lightly against the panel.

Brian
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post #5 of 10 (permalink) Old 06-06-2012, 10:55 PM
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Quote:
Originally Posted by versysxxx View Post
...How tight should those bolts be?...Brian
Quote:
Originally Posted by Bluegenes View Post
...As to how much the bolts should be tightened? I wish I had a good answer.....just enough, but not too much is how I do it now.
I use blue Loctite on those whenever I remove/replace them. I use a 1/4" ratchet with my hand held around the ratchet-head NOT at the end of the handle for tightening. That way I haven't overtightened them (yet!!!).



Every few times when they're removed I run them thru a die, and a tap thru the thread insert, to clean out the old Loctite, and make them easier to turn.


Ed
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post #6 of 10 (permalink) Old 06-06-2012, 10:59 PM
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Yes, the panels are ABS. I had my left side crack for no apparent reason and never been off the bike. I suspect it was cracked when I bought it but then spread. I used a sanding drum on my Dremel to V out the crack a bit and put in Devcon Plastic Welder (a two part like epoxy). Came out fine.

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post #7 of 10 (permalink) Old 06-07-2012, 09:21 AM
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Can you post some pic ?
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post #8 of 10 (permalink) Old 06-07-2012, 10:37 PM Thread Starter
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Can you post some pic ?
Here it is. I have duct tape behind to hold it together.

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post #9 of 10 (permalink) Old 06-08-2012, 08:50 AM
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Here it is. I have duct tape behind to hold it together.

Wo ... That's pretty intense

Have you ever droped your V ?

Have to check mine for starting crack ...

Hopefully, you'll be able to do a clean fix with all the solution mentioned

Good luck

Take care

LOP
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post #10 of 10 (permalink) Old 06-08-2012, 09:16 AM
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Here it is. I have duct tape behind to hold it together.


That is nothing.
Skilled hands can make that look like new. Just take it to a good body shop.

Mine was in pieces so it was patched and glued back and it looks great. Apart from the wrong color.
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