02-09-2014, 02:21 AM #1
09 FZR Split pump tunnel (with pics)
went for a run with a mate around some local waters, we were doing a few WOT runs around 75mph.
coming home we were just mucking around doing mid range runs when all of a sudden he just left me for dead, then my ski started to misfire then died in the arse.
turned around and looked in the hull I couldn't see the battery for water
Got it towed until I could start it (engine gulped in a bit of water) back to the boat ramp and saw the problem right away
now I reinforced the tunnel with 5 layers of carbon fibre when I got the ski at 15hrs, it's split the nano and just forced the carbon apart from the nano
it seems like the water has built up huge pressure down the side of where the intake grate fits in against the transom and forced it all to split.
I'm at a (hard) 86hrs now.
The split is about 9" in length and split right round in a triangular shape
im going to take it in and get it repaired properly, as it's in such a crucial part of the ski.
can anyone please tell me what else can be done to prevent this happening again eg. Re enforcing/skin the whole tunnel or sealing the mating surface flush between the tunnel and intake grate.
any info would help greatly as thers a few of us with modded FZ's that would also like to prevent this problem from happening to start with.
02-09-2014, 03:09 AM #2
It looks like you have left the oem reinforcements. I am looking at doing this very soon. I am pretty sure it's best to remove the those. My guess is that there is a void in the glue on that side for it to only crack there.
02-09-2014, 03:35 AM #3
Forgot to mention, that the Yamaha plastic reinforcement was removed and then put in the bin
Then the glass was rough ground for the new resin/glass to bite, the only factory bit left there is the shaft sleeve housing.
something hasn't gone right, but it's only gonna be more money now. But once it's running again Ill start buying more parts to spank FZSAUST
02-09-2014, 03:56 AM #4
Now I see it. I can see where the white plastic pieces were screwed into. I am going to grind them off. What weight carbon did you use?.
02-09-2014, 04:07 AM #5
I would be looking to make an aluminium liner to take the pressure ! Yamaha had the answer back in 97-99 GP1200 tunnel being all alloy . Seems like the Nano cell will fail eventually.
02-09-2014, 04:29 AM #6
- Join Date
- Oct 2011
- Sunshine coast QLD
02-09-2014, 04:50 AM #7
db2540- not sure of the weight, i know it's the 2x2 twill from the local glass shop. It's on the thicker side, I never thought this would happen from the amount of glass I applied, but obviously there was a weak spot.
i really like the idea of a alloy liner that would be kick arse!
02-09-2014, 04:58 AM #8
What has probably happened is that as the tunnel has been flexing the epoxy has let go , I made a carbon fibre one just like yours but I used a release agent so it would come off after the epoxy set . I cleaned it up and stuck it back on with 5200 . Just my 02 cents ..
02-09-2014, 05:56 AM #9
02-09-2014, 07:09 AM #10
Get a coco tunnel reinforcement piece from the green hulk store
I also think the fully sealing the intake grate would help
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