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  1. #1
    SLAP~YA's Avatar
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    09 FZR Split pump tunnel (with pics)

    Hey fella's

    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.

    cheers


  2. #2
    db2540's Avatar
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    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.

  3. #3
    SLAP~YA's Avatar
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    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

  4. #4
    db2540's Avatar
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    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?.

  5. #5
    Adam's Avatar
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    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.

  6. #6

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    Quote Originally Posted by SLAP~YA View Post
    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

    Lol ok this will never happen I have seen the light and running for it

  7. #7
    SLAP~YA's Avatar
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    Quote Originally Posted by fzsaust View Post
    Lol ok this will never happen I have seen the light and running for it
    Little do you know what's to come

    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!

  8. #8
    Steve-m31164's Avatar
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    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 ..

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  10. #9
    db2540's Avatar
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    ^ I will be doing this.

  11. #10
    fx160's Avatar
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    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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