Article [13] ST1300 - Affordable Lower Cowl Replacement

[BentAero]

PROBLEM:
Lower cowl replacement w/ heat shield.

YEARS EFFECTED:
?04-?07

ISSUE:
Lower cowl for ?03 model is $70.43,
?04-07 cowl is $202.86 (Ron Ayers.com)

We?re going to convert an ?03 model cowl into an ?04+
with some common tools in
20 minutes, saving $132.43!

Due to some over exuberant riding, I wore a hole thru the
lower cowl on my ST13 by dragging it on the ground.

The ?03 and ?04-07 panels look the same from the exterior.

The only difference is the heat shield mounted to the
inside of ?04-07 model years.

Remove the heat shield from the old cowl. The
plastic stud will likely be melted.

Use side-cutters and snip off what?s left off the plastic stud.

After cutting it, carefully pry off the metal tension
clips. You?ll reuse these.

There are three rivets holding the heat shield on at
the bottom of the cowl. Grab the tail of the rivet
and drill off the head.

Separate the heat shield from the old cowl. Remove
the 3 special washers that the attachment bolts go thru.
Install them in the new cowl.

Now that you?ve drilled out the rivets, try to remove the
washer from each of the 3 rivets. This may be easier said
than done, you may choose to just replace them with new
ones. They are readily available next to the rivets at your
local hardware store.

Using 1/8? dia., zero to .250? depth range aluminum rivets
(w/ washers) Pop-rivet the heat shield to the new cowl.
Reinstall the metal tension clips on the plastic studs.

You?re done. Reinstall and go ride!

 

[Mellow]

Re: ST1300-Affordable Lower Cowl Replacement

I just added this back - Thanks Gary!

 

[FJRHank]

Re: ST1300-Affordable Lower Cowl Replacement

yup very kewl, thnx. This is definately a good thing to have available!!

Regards,

 

[GitGoFast]

Re: ST1300-Affordable Lower Cowl Replacement

Can't see pictures ...

 

[uptoblackwood]

Re: ST1300-Affordable Lower Cowl Replacement

No images?

Forest

 

[wjbertrand]

Re: ST1300-Affordable Lower Cowl Replacement

Dreaded little boxes with red "Xs" in them instead of pics.

 

[Rob Hephner]

Re: ST1300-Affordable Lower Cowl Replacement

I have cool blue x's

 

[Hashimoto]

Re: ST1300-Affordable Lower Cowl Replacement

Nope, the X's are definitely red.
I guess Apple has decided for you that red is too harsh a color to indicate that something isn't working correctly. The soothing blue color is used to give the impression that everything will be OK, nothing ever goes wrong on a Mac.
Sorry Rob, I just couldn't help myself....

 

[nm6r]

Re: ST1300-Affordable Lower Cowl Replacement

Yup. Red X's here too (not a Mac).

As far as this thread goes, there is yet a less expensive way of resolving the problem of a hole worn through the lower cowl.

For apx. $10 IIRC, they can be repaired better than new.

JBWeld does the trick for repairing the hole. Duplicolor makes a paint that matches the lower cowl perfectly. Notice I said, "better than new"? Once repaired, the cowl can be scraped and it takes a lot more to wear through and can be easily touched up.

Ray

 

[Mellow]

Re: ST1300-Affordable Lower Cowl Replacement

Those images were lost in the great server crash of 2007...

But, I remember the pics and it's all pretty obvious once you get the items and you look at what you have and the 2003 parts and you'll see what needs to be done.

Hopefully, the next person that gives it a shot will create some pics for us and they'll be on the site again.-

 

[Nevada]

Re: ST1300-Affordable Lower Cowl Replacement

Replacement lower cowl info would be very handy for me. My left side lower cowl suffered a high energy impact (methinks a high heel spike) when the temperature was in the teens, so now I got a hole there. Picatures would be nice...

 

[Mellow]

Re: ST1300-Affordable Lower Cowl Replacement

TA DA!!! Pics recovered... check the first post...

 

[Nevada]

Re: ST1300-Affordable Lower Cowl Replacement

:bow1: :bow1:

Mellow be DA MAN!

:bow1: :bow1:

 

[Mellow]

Re: ST1300-Affordable Lower Cowl Replacement

The real credit goes to Gary - BentAero - who put this together in the first place.

 

[MidLife]

Re: ST1300-Affordable Lower Cowl Replacement

Wondering if anybody has mounted the latest lower cowls (heat shielded) on an 03 and noticed a difference as far as heat on the feet/legs?

 

[abiter]

Hello Guys,
I just did this Mod on my 2009 ST1300P. I went over a curb behind a BMW during training and cracked the left lower cowl. I was told.."nobody will notice, so we "the City" won't pay $250.00 to replace it" .. I told my SGT "I would notice" and took care of the problem myself. It worked great.

 

[wjbertrand]

Hello Guys,
I just did this Mod on my 2009 ST1300P. I went over a curb behind a BMW during training and cracked the left lower cowl. I was told.."nobody will notice, so we "the City" won't pay $250.00 to replace it" .. I told my SGT "I would notice" and took care of the problem myself. It worked great.

Hi Anthony, noticed your "Ventura, CA" location. What city do you work for as I think Ventura is using BMWs or have they begun to change them out for STs?

 

[Superdirk]

And I had my hopes up thinking this was a cheapo upgrade for pre-'04 models... Guess there is no such thing as a free lunch..

 

[Mellow]

Hi Anthony, noticed your "Ventura, CA" location. What city do you work for as I think Ventura is using BMWs or have they begun to change them out for STs?

 

[wjbertrand]

^^^^
Thanks Joe, Fillmore is just a few miles inland of Ventura on CA 126. Didn't realize they were runnin' the STs. I think Thousand Oaks, another Ventura county city is runnin' them though.