GEN II Plastic and Cowling Removal

[Bill G]

Thanks, RossKean. Pricing and availability suggest that may be the best route. Partzilla lists the part (OEM 99999-03841-00) for $139.65. The seal is relatively thick, rubberlike, flexible PVC, which you correctly identified. I’ll try to repair the tear, then see about affixing the seal to the cowling with 3M trim tape after thoroughly cleaning everything.

 

[RossKean]

Thanks, RossKean. Pricing and availability suggest that may be the best route. Partzilla lists the part (OEM 99999-03841-00) for $139.65. The seal is relatively thick, rubberlike, flexible PVC, which you correctly identified. I’ll try to repair the tear, then see about affixing the seal to the cowling with 3M trim tape after thoroughly cleaning everything.

The fiche for the '07 shows a part called a "seal set" - the one you pointed out. Depending on what is damaged, you might be able to use seal parts from a later Gen II. (I think the nose piece is essentially the same.) Have a look at the fiche for the 2011, below. It uses one relatively expensive part and four cheaper parts to make up the complete seal (parts 44-48). If nothing is badly damaged then you can use the seal from your bike after thorough cleaning and degreasing. The 3M product (double sided-trim tape) is excellent if surfaces are properly cleaned.

Yamaha Motorcycle 2011 OEM Parts Diagram for Cowling 1 | Partzilla.com

Buy OEM Parts for Yamaha Motorcycle 2011 Cowling 1 Diagram

www.partzilla.com

Edit: Let's not mess up this excellent "How To" thread with specific issues or problems that are not directly related to the initial post. It is appropriate to start a new thread with reference to this one. If nothing else, this recent flurry of activity popped it up to recent threads where newbies might see it. Perhaps it should be a "sticky" in the technical section.

 

[Bill G]

The fiche for the '07 shows a part called a "seal set" - the one you pointed out. Depending on what is damaged, you might be able to use seal parts from a later Gen II. (I think the nose piece is essentially the same.) Have a look at the fiche for the 2011, below. It uses one relatively expensive part and four cheaper parts to make up the complete seal (parts 44-48). If nothing is badly damaged then you can use the seal from your bike after thorough cleaning and degreasing. The 3M product (double sided-trim tape) is excellent if surfaces are properly cleaned.

Yamaha Motorcycle 2011 OEM Parts Diagram for Cowling 1 | Partzilla.com

Buy OEM Parts for Yamaha Motorcycle 2011 Cowling 1 Diagram

www.partzilla.com

Edit: Let's not mess up this excellent "How To" thread with specific issues or problems that are not directly related to the initial post. It is appropriate to start a new thread with reference to this one. If nothing else, this recent flurry of activity popped it up to recent threads where newbies might see it. Perhaps it should be a "sticky" in the technical section.

Thanks, RossKean. Good to know. However, I didn’t see your reply until already having thoroughly cleaned the cowling interior, applying the 3M trim tape and reinstalling the original seal. If it doesn’t work out, I’ll go to your suggestion as my Plan B. I appreciate your insights on this.

 

[franciscoldz]

Thank you @kaitsdad. I was able to remove the whole fairing with only busting a couple of fasteners. As per your advice, I did have spares.

Does anyone know what this connector is (not the ABS one, the one with the metal end with the plastic white plug)? And does it go there? Inserted into the metal structure?

I think it is the thermistor, but I don't know if it should go like that, hanging.

Thank you!

 

[RossKean]

Thank you @kaitsdad. I was able to remove the whole fairing with only busting a couple of fasteners. As per your advice, I did have spares.

Does anyone know what this connector is (not the ABS one, the one with the metal end with the plastic white plug)? And does it go there? Inserted into the metal structure?

I think it is the thermistor, but I don't know if it should go like that, hanging.

Thank you!

View attachment 4114

It is the ambient temperature sensor and is not connected to anything.

 

[franciscoldz]

It is the ambient temperature sensor and is not connected to anything.

Thank you.

 

[kaitsdad]

Thank you @kaitsdad. I was able to remove the whole fairing with only busting a couple of fasteners. As per your advice, I did have spares.

Does anyone know what this connector is (not the ABS one, the one with the metal end with the plastic white plug)? And does it go there? Inserted into the metal structure?

I think it is the thermistor, but I don't know if it should go like that, hanging.

Thank you!

View attachment 4114

It is the thermistor, and it's just hanging there, held in by a small zip tie. All good.

 

[PhatAir4Me]

@kaitsdad I see you are still active on the forum. Thank you for taking the time to put this together. Priceless! Had it all torn down in under 2.5 hours!