Article [13] ST1300 - Affordable Lower Cowl Replacement

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!