My right cowling flew off

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Hi all,

Just relating an incident I had two days ago.

Last Sunday I decided it was getting chilly and moved the cowlings out to redirect air.

I had moved them out this summer and (for me) felt it was warmer with the cowlings out at the time, but then returned them to the in position. I'd like this not to turn into an inny versus outy discussion, it is merely what I decided (TIA). I checked the cowlings top and bottom for tightness each day this week, as I am nutty about this bike.

Three days later on Tuesday. I checked the cowling tightness, along with my usual pre-flight check and went for a ride after work. During a spirited acceleration, going (?) 90+ ... it felt like a baseball hit me just below the right knee -- WTF?!! :eek:

I pulled over and the right movable cowling had sheared off but the tabs and fasteners were still in place. A soccer mom in a van (bless her heart) brought my cowling piece to me. The indentation for the forward fastener was punched out and the area around the back fastener indentation was cracked. A couple minor scuffs. The tabs on the bottom were in place. I checked at home more closely. The plastic had deformed and looked like a bowl, shaped upward around the forward faster screw and was still in place with the rubber washer. :unsure: The left cowling was fine.

Yesterday I drove over to my dealer and my (trusted) mechanic who is the service manager looked it over and said he'd put in for some wawa (his term for warranty replacement). :)

No, I don't have pics because I haven't embraced the 20th century by obtaining a digital camera. Hopefully the description is accurate enough that you can understand.

So, did I just screw the pooch and was it my bad, or a design flaw causing wind in the outboard cowling position to get trapped at higher speeds, and forcing the deformation and failure at speed? Anybody else had this happen? I thought somebody (? Fencer) had a failure of the right cowling at speed, but my memory may not be serving me.

 
Yea, I think someone coming home or going to WFO had the same thing happen. I worry about it, not because I change the position, but because I have had the tupperware off the bike so many times now...

 
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This sucks!!! I've been riding with mine out for a couple months now and have been 100+ a few times but now that I hear this...back in they go.

 
Yo, SPU -

I've had the plastic off of Wonky more times than I care to admit. Those 'heat flaps' are tricky - the problem is these little spring clips on the bottom edge:

102042685-L.jpg


These are the guys that hold the bottom edge onto the bike. And they can GIVE THE APPEARANCE of being in the groove and tight - when they really aren't.

DAMHIK

And if you're lucky, it will just fall off the bike the next time you remove the primary fasteners. :blink:

So - (this is just a theory) - your right panel wasn't properly clipped into the fasteners when you moved it outboard -

and when moved out, it literally created an air scoop -

Inboard:

102042655-L.jpg


Outboard:

102042673-L.jpg


So - to finish my theory - there may have been only one of the two clips fastened when you moved it outboard - (or perhaps none)- the scoop did it's job, pressure built, and it tried to fly.

Just a suggestion to all the 06 owners out there - when you have a minute, pull the fasteners, slide the panels outboard and then pull them out another inch or so - and make sure that those clips are fastened. You will notice that they are tight, if properly fastened.

This may be related to assembly (gee - have we seen that somewhere else? ) or a faulty clip?

Just out of curiosity, what shape are the two clips in? are they bent, or torqued?

Sounds like you need to call Gary McCoy - and check your left scoop !!

EDIT: Oh yeah - Like Warchild says, " get a digital camera! "

 
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Thanks Kaitsdad,

Possible.

My clips look like yours. No bent parts/clips or anything.

I did have the cowlings outboard this summer for a couple days when the big discussion was going on about which position helped with heat. It didn't fly off then. Haven't had that panel off at all since delivery mid-May, and all I did was slide the top portion an inch to put the fasteners back in -- but then again maybe I had just been lucky.

Also, before the ride I tugged the upper portion and it was tight, and tugged the bottom on both sides fore and aft because I remembered that one rider had it fly off, and I knew the clips could be tricky from reading posts (an aside, I thought about taking it off but didn't want what happened to happen, so I "left well enough alone"). But I admit I have never taken the cowling off completely, to make sure the clips were engaged correctly since delivery.

What makes me think you could be right is if the bottom tabs were engaged correctly in the metal clips, wouldn't one or both be bent or broken? Or do they disengage so easily that with the failure of the upper forward section, the natural movements would have caused the tabs to diengage?

Just thinking out loud. Still puzzled.

 
Wasn't me.

I have had my pannels in and out several times and several more "spirited" runs than you describe.

It will be interesting to follow though.

 
It was me.

I'm not savvy enough to link to my earlier postings and pics, but they're on the board somewhere if someone wants to find it for my lazy ***.

I had never adjusted mine, I just left them in from when I picked up my bike in May at Sunnyside. Actually, I take that back. WC was there the day I picked up my bike and we moved the side that didn't come off.

It does hurt when that thing hits you in the leg. I didn't know what the hell was going on.

Seth at Sunnyside spoke with Yamaha and they decided it was a factory repair/replacement, as we figured it had not been clipped in properly before I took delivery. Last month, I went up, had the new piece put on after it came in and the bike is as good as new.

Oh, and you're correct, it was on the way to WFO. It killed me to have that piece sitting on my bike at the hotel. Sigh.....

Pig

 
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Sorry for the flying parts.

If everyone had read the consumer report on the new FJR and there air diversion wings, they would have know there was a design flaw in them. As the report goes on in length The Japanise product council issued a recall of the FJR for the 06 models. They would have repaired them but I see you did not get your notice in time.

Being that the recall program is over you will have to ship it directly to YAMAHA using there carrier JAPAN PARCEL SERVICE. hope this helps

It has been a pleasure spreading the good word :yahoo: weekend rider

 
Pig, SPU,

Just for grins, what are the last 4 digits of your vin numbers?

Pig, I see you took delivery of yours at Sunnyside - SPU, where did you take delivery?

Wouldn't it be interesting if the vin numbers were consecutive - probably built the day that the line manager's third cousin's son started on the assembly line .....

 
Pig, SPU,

Just for grins, what are the last 4 digits of your vin numbers?
last 4 on mine is 0955
Last four on mine is 0965 with a manufacture date of 03/06. Bought and Delivered at Roseburg Power Sports in Southern Oregon.

Woke up with a thought this morning: The dealership replaced my instrument cluster three weeks ago or so.... hmmm

Guess I'll see if Yamaha replaces the part. Either me, Yamaha or the dealer screwed up. Unless we get more incidents over time (hope not) I don't think a design flaw can be assumed. Just my $.02 at this point.

Oh yeah, I'm going to buy a digital camera, then bug yuz guys how to use the damn thing :****: :p

 
Woke up with a thought this morning: The dealership replaced my instrument cluster three weeks ago or so.... hmmm

Well - that's an interesting coincidence, isn't it?

I just browsed through the shop manual - and you have to remove the side panels to remove the front cowling, in order to remove the "Meter Assembly." Starts on page 4-9.

On page 4-10 of the reassembly process, "Installing the side panels" :

"Be sure to fit each pin "a" on the side panels "1" into the groove "b" in it's corresponding hinge on the side cowling"

Maybe you should call the service manager at your dealer ?

Let us know what happens, ok?

 
Woke up with a thought this morning: The dealership replaced my instrument cluster three weeks ago or so.... hmmm

Well - that's an interesting coincidence, isn't it?

I just browsed through the shop manual - and you have to remove the side panels to remove the front cowling, in order to remove the "Meter Assembly." Starts on page 4-9.

On page 4-10 of the reassembly process, "Installing the side panels" :

"Be sure to fit each pin "a" on the side panels "1" into the groove "b" in it's corresponding hinge on the side cowling"

Maybe you should call the service manager at your dealer ?

Let us know what happens, ok?
Will do Hal

 
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