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  1. #1
    Gus13letter's Avatar
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    HOW TO: Yamaha FZR tunnel reinforcement install.

    Over the past couple of years I have had several folks reach out to me asking how to install the Coco tunnel reinforcement. Since I recently installed one I thought I would post up a quick how to.
    Here is the link to order the reinforcement. http://www.4-tecperformance.com/inde...oducts_id=1927

    Steps.
    • Remove all rear seat plastics and center seat brace from ski.
    • Remove all hoses from transom. Note where they go for later. You do not need to remove any of the cables.
    • Remove all of the exhaust hoses and water box. You should be able to leave the exhaust exit elbow tube.
    • Remove the two little bolts on top of the tunnel holding white plastic pieces on.
    • Evenly heat the white tunnel plastic piece up till it is very hot. Should be smoking with heat gun. Pop it off with a screw driver. Do the same for the other side.
    • Grind down the little nubs on top of the tunnel where the two bolts were
    • Make sure all of the glue is off the tunnel and it is clean.
    • Test fit the reinforcement pushing it as far back as possible. You should notice there is a slight gap between the top of the tunnel and the reinforcement. This is ok for now.
    • While reinforcement is in place, mark the bottom of the hull liner outlining the reinforcement feet. This is where the reinforcement feet sit. Pull the reinforcement out.
    • Carefully cut the liner out with a Dremel or something similar and remove the liner pieces. You only want to cut through the liner. Be careful not to cut into the hull.
    • Test fit the reinforcement and make sure it sits 100% flush with the hull and tunnel
    • Sand the entire area where the reinforcement comes in contact with the tunnel and hull really well with 60 grit sandpaper. Also sand the entire reinforcement where it will come in contact with the hull really well with 60 grit sandpaper. Make sure all of the corners are sanded.
    • Clean everything really well with Acetone
    • Test fit one last time
    • Apply Six-Ten epoxy or your choice of 2 part epoxy to all areas of the mating areas of the tunnel, hull, and reinforcement. Make sure you have a nice even coat on the parts to eliminate air pockets.
    • Install reinforcement. Make sure it sits down flush and back as far as possible. You can use a 2X4 to wedge the reinforcement in there.
    • Even out the epoxy around edges and at the base and then clean up excess epoxy to make the install look clean.
    • Let cure for a day or suggested cure time for your epoxy.
    • Re-install all the hoses and top deck components.
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    Last edited by Gus13letter; 05-14-2014 at 07:47 AM.


  2. #2
    Gus13letter's Avatar
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    Pics. You can see where liner was cut out to allow the reinforcement to sit down onto the hull.
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  4. #3
    r33pwrd's Avatar
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    nice job! wish someone had pictures that good when I did mine! the liner thing is scary the first time

  5. #4
    Gus13letter's Avatar
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    Quote Originally Posted by r33pwrd View Post
    nice job! wish someone had pictures that good when I did mine! the liner thing is scary the first time
    Thanks! Yeah, no kidding. That's why I figured I'd post this up.
    Yeah, it's been a couple of years since I did mine so when I did this one, I was very cautious. Not to bad though. Even if you knick the hull it's not a problem.

  6. #5

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    Very nice write up and this should be a sticky.

  7. #6
    ArslanD's Avatar
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    Gus, this needs to be a sticky. Saved many hours of frustration, but there still will be frustration. Thanks man great work and detail.

  8. #7
    Gus13letter's Avatar
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    Your very welcome guys. Glad I could help. I was surprised there wasnt one and figure with all the folks reaching out to me about it, I could help with one post and pics. Good luck with your installs. It really isn't a bad job to do.

  9. #8
    64physhy's Avatar
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    When I did mine, I filled the cut out area of the liner with extra epoxy so it filled the gaps around the feet of the reinforcement and ended up being flush. Also, on mine, I didn't need to heat the white plastic pieces, they popped off fairly easily.

  10. #9
    Kristian Keppel Waterholics's Avatar
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    Excellent write up Gus. Going to get these installed on my ski pronto.

  11. #10
    db2540's Avatar
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    I did this today. Not the funnest thing in the world but well worth it. Cheers for the write up. BUMP.

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