Help, poor fitting cowl


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Stew
Posts: 264
Joined: Mon Oct 23, 2017 10:40 am
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Motorcycle: 2000 GL1500 SE
2005 Honda CRF230F

Previous bikes:
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1993 Honda Elite SR
1986 Honda CR125R
1979 Yamaha GT80

Help, poor fitting cowl

Post by Stew » Thu Dec 14, 2017 1:11 am



I need help figuring out the cause of my poor fitting cowl. I've had this off a few times now and for the life of me cannot get it to fit good. It was like this when I took ownership about six weeks ago but I'd like to fix it. The only causes I can think of would be the radiator grill or the panel directly above the cowl mounting too high or the cowl itself mounting too low but I don't see any bent brackets where any of these parts fasten too that would be causing such a bad fit, but something is obviously not right. :?:

As I'm looking at the picture more, it HAS to be a mounting issue just with the cowl. Everything above it fits and lines up fine, just the cowl sits too low. When mounting it, it fits a little better than in the pic but it kinda pops back down after riding it.





Winging it every chance I get 8-)

19,119 miles when I got it from dad Oct 15, 2017 --- 22,072 miles and counting as of June 14, 2018!

dvcruz
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Location: San Jose, Ca
Motorcycle: 1993 GL1500 Aspencade
1983 GL1100 Interstate

Re: Help, poor fitting cowl

Post by dvcruz » Thu Dec 14, 2017 3:31 am

Hi. You didn't mention the 3 screws that hold the cowl in place. There is one in the middle and one on each side. Also, as you look ar the pic you provided, on the right hand edge of the cowl there is a tricky little tab that has to clip onto another tab on the plastic piece above the cowl. There is a tab on both sides. Judging by the gap size I see, I don't think those tags are engaged.
DVC
Back in the San Jose area for now...

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Stew
Posts: 264
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Motorcycle: 2000 GL1500 SE
2005 Honda CRF230F

Previous bikes:
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1993 Honda Elite SR
1986 Honda CR125R
1979 Yamaha GT80

Re: Help, poor fitting cowl

Post by Stew » Thu Dec 14, 2017 10:52 am

The three screws are in, and I just replaced the clipped-on nut on the right. When I first put it back on, the cowl's tabs are engaged with the fairing but the gap is big enough that the vibrations from riding pops them out and the gap looks even worse, like in the picture.

Since those three screws holding the cowl are screwed in correctly, you'd almost think those three brackets are bent down causing the excessive gap, but they don't look to be so. I'll look again but this is a head scratcher!
Winging it every chance I get 8-)

19,119 miles when I got it from dad Oct 15, 2017 --- 22,072 miles and counting as of June 14, 2018!

MalcolmX
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Joined: Tue Nov 28, 2017 7:33 pm
Location: Tucson, AZ
Motorcycle: 1994 Interstate, 1996 VFR750

Re: Help, poor fitting cowl

Post by MalcolmX » Sat Dec 16, 2017 11:12 am

I have the same problem on a recently purchased, 1994. Noticed a bad gap on one side, just after purchase.
Spent a couple hours with it off, squidging other panels, used hi-test outdoor velcro on some upper pieces, played with mounting screws- at the end, I moved the gap to the other side!
And going for a ride shakes them down for about the same gap on both sides.
Suppose there is no solution, except for ol' trial and error :P

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Erdeniz Umman
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Re: Help, poor fitting cowl

Post by Erdeniz Umman » Sat Dec 16, 2017 6:39 pm

You could try removing the curved piece over the lower cowl and the lower cowl first.

Then, check the two rubber grommets on the lower fairings (over the fog lights), are they in place, and in good shape?

Also if necessary, you could bend the brackets on both sides where the lower cowl is mounted a little bit forward, so that they will raise the cowl up, repeat this until it meets the upper tabs.

Then install the curved piece on the lower cowl first and then push it into the grommets.

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lamasue
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Location: Winslow,maine
Motorcycle: 2000 1500se

Re: Help, poor fitting cowl

Post by lamasue » Sun Dec 17, 2017 8:50 am

My 2000 dosnt fit snug there either

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Stew
Posts: 264
Joined: Mon Oct 23, 2017 10:40 am
Location: Smokey Point, WA - USA
Motorcycle: 2000 GL1500 SE
2005 Honda CRF230F

Previous bikes:
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1993 Honda Elite SR
1986 Honda CR125R
1979 Yamaha GT80

Re: Help, poor fitting cowl

Post by Stew » Thu Mar 01, 2018 9:14 pm

I'd like to revisit this, I took a couple more pictures. Keep in mind this bike was bought brand-new by my father, he absolutely has never crashed it and I've had the lower fairings and cowl off and I don't see anything amiss. Nothing looks bent, broken, etc but there is a big difference from left to right how these parts are fitting so SOMETHING has to be going on. I haven't yet removed the lower exhaust shields where the foot warmer vents are so maybe it's something behind those?


Winging it every chance I get 8-)

19,119 miles when I got it from dad Oct 15, 2017 --- 22,072 miles and counting as of June 14, 2018!

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WingAdmin
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Re: Help, poor fitting cowl

Post by WingAdmin » Thu Mar 01, 2018 9:57 pm

I would take those parts off and see if the mounting bracketry underneath has been bent.

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Bluewaterhooker0
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Motorcycle: 1997 Goldwing GL 1500 SE

Re: Help, poor fitting cowl

Post by Bluewaterhooker0 » Thu Mar 01, 2018 11:09 pm

I don't have an answer to your question, but if you look at your photos, and the relation of the lower fairing + Cowl to the crash bars, something certainly seems amiss.
I would think the engine and crash bars would be in mirrored positions, and those plastics would also mirror their distance and relations to the bars. Yours don't appear to.

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Stew
Posts: 264
Joined: Mon Oct 23, 2017 10:40 am
Location: Smokey Point, WA - USA
Motorcycle: 2000 GL1500 SE
2005 Honda CRF230F

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2003 Honda Ruckus
1993 Honda Elite SR
1986 Honda CR125R
1979 Yamaha GT80

Re: Help, poor fitting cowl

Post by Stew » Fri Mar 02, 2018 12:16 am

I know, this is driving me crazy. I was trying to compare to pics online to see if the left side is pushed forward or if the right side is pushed back and it looks like it could be a little of both. When I get a chance I'll take everything back off and look again and if I'm still not seeing the problem maybe I could meet up with someone local and actually compare some measurements of a few of the fairing/cowl mounting points to see what in the heck is off. I will get to the bottom of this :P
Winging it every chance I get 8-)

19,119 miles when I got it from dad Oct 15, 2017 --- 22,072 miles and counting as of June 14, 2018!

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Stew
Posts: 264
Joined: Mon Oct 23, 2017 10:40 am
Location: Smokey Point, WA - USA
Motorcycle: 2000 GL1500 SE
2005 Honda CRF230F

Previous bikes:
2003 Honda Ruckus
1993 Honda Elite SR
1986 Honda CR125R
1979 Yamaha GT80

Re: Help, poor fitting cowl

Post by Stew » Sun Mar 04, 2018 6:40 pm

Ok I'm ready to call this one fixed, not perfect but good enough. Still not sure how the cowl got to fit so bad, all of the brackets are welded on and not adjustable. What I ended up doing was slightly "adjusting" the three cowl brackets by tapping with a hammer, and elongating the screw holes in the plastic cowl slightly more with a round file. Definitely better.









Winging it every chance I get 8-)

19,119 miles when I got it from dad Oct 15, 2017 --- 22,072 miles and counting as of June 14, 2018!

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Erdeniz Umman
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Re: Help, poor fitting cowl

Post by Erdeniz Umman » Mon Mar 05, 2018 1:33 am

Actually, the brackets are not made from a hard metal, and probably they are being bent by the time due to the weight of the pieces on it or some other reason.

You could use an adjustable wrench like below to adjust the angle of the bracket instead of a hammer. Just adjust it to hold the bracket from the bottom and pull or push the handle a little until you find the correct point.
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joeincalif
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Re: Help, poor fitting cowl

Post by joeincalif » Mon Mar 05, 2018 9:50 am

Definitely looks better. Nice job.
Image
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ct1500
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Re: Help, poor fitting cowl

Post by ct1500 » Mon Mar 05, 2018 5:19 pm

I have seen where owners mount the side marker light under the tabs between the plastics. When that is done the side light will be recessed slightly instead of flush with the outer painted plastic and will throw off the final fit.
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Stew
Posts: 264
Joined: Mon Oct 23, 2017 10:40 am
Location: Smokey Point, WA - USA
Motorcycle: 2000 GL1500 SE
2005 Honda CRF230F

Previous bikes:
2003 Honda Ruckus
1993 Honda Elite SR
1986 Honda CR125R
1979 Yamaha GT80

Re: Help, poor fitting cowl

Post by Stew » Mon Mar 05, 2018 6:01 pm

Hmmm. I am now wondering how I have those mounted, I have had those off when I was doing other maintenance and needed to remove the lower side fairings. The lights look flush so hopefully they're mounting correctly...


Winging it every chance I get 8-)

19,119 miles when I got it from dad Oct 15, 2017 --- 22,072 miles and counting as of June 14, 2018!

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