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Melting instrument panel and cockpit

11K views 24 replies 12 participants last post by  Walter Lea Thomas  
#1 ·
I bought a 2011 DL 650A brand new from Suzuki of Hollywood after I read a lot of very positive online feedback about the bike. The bike is used for daily commuting up and down Is 5 and 405, and I have over 20K miles on it so far.

While the engine is flawless the front of the bike (instrument panel and cockpit) is terrible. The instruments bubbled up around the mounting screws, and never went back to the initial flat surface again.

Additionally, the part the holds the wind shield bracket warped in the center. In other words, after just over two years this brand new bike looks like S* in places that I can't avoid looking at.

Suzuki's obnoxious service reps refuse to replace the instrument panel as well as the warped plastic although I bought the Suzuki extended warranty because my issues are due to "corrosion" which the warranty excludes. I'm so sick of looking at the deformed parts that I decided to replace them out of pocket with something made of metal, I'm thinking brushed aluminum.

Does anybody here know of a shop that would be capable and willing to work on a job like this? BTW: if that void the warranty I don't care becasue the warranty is worthless to begin with. Thanks for your input!
 
#3 ·
go back to dealer

tell them that plastics don't corrode and get busy honoring the waranty - and if they don't understand "corrosion" ask them to consult with a lawyer about the english language

metals corrode, plastics degrade (or a sijmla rword)

if they did not use the word degraded in the warranty, they got no leg to stand on

BTW - is your windscsree OEM or aftermarket?

Exactly which pievces have been affected. By color and part number /name from the Factory Manual or parts fiche.
 
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#4 ·
What TMCGee said about some aftermarket brands of windscreens...they focus the sunlight and cook the dash. painting the inside black is the fix for some but it's usually after the damage is done unless you read all the posts about problems.
I'd heard of it on BMW's. The melted Suzuki I wasn't aware of.
I made a dash from some scrap metal I had and that sort of thing would hide the damage from view and keep it from happening in the future.
 
#11 ·
The dials bubbled on my bike, a 2011 DL 650A. Saturday I visited my mechanic for something else, and there was another guy with a 2007 650 whose dials bubbled in the exact same places as mine, around the mounting screws. Therefore, this doesn't seem to be an issue with my bike but rather with many 650 Wees regardless of model year.
 
#5 ·
"Plastic corrosion" that alone states just how idiotic that dealer is. For sure some aftermarket screens are known for focusing too much heat in one area like a magnifying glass, I hope you are able to get this resolved but I am betting it will be out of your own pocket. I have a V-Stream on mine, and I will place a mircofiber towel over my dash if it is going to be parked in hot direct sunlight for any long periods of time.
 
#6 ·
#8 ·
My 2010 Wee had the same issue but to a lesser extent. I installed a radar shelf to conceal/hide the problem and to protect it in the future (from sun, rain, etc). Out of sight ... Out of mind has worked for me. I also now keep a small towel to drape over the dash area if it will be parked for an extended period of time.

It is disappointing ... But if that is the biggest issue I have to deal with re. this bike then I can live with it. I just wish in hind sight that I had installed the shelf before it got damaged.
 
#9 ·
The subject of dash "branding" has been long ongoing in the ST1300 boards, and leads to bikes with a Givi windshield installed. In fact, Givi does include a warning about that very thing with their windshield. A simple solution is to carry a light cloth windshield cover that you can quickly slip over the shield when you park the bike. Or simply park facing the sun to avoid the dash branding from occuring. So far, I've had no issues with the Givi on my '09 Wee.
 
#10 ·
Melting: additional information

First off: thanks to all who replied. Instead of replying in turn to all the replies I will attempt a summary reply to all your replies.

The parts affected are the two dials for speed and rpm. I don't have the part # at this point. The dials are held in place by 4 small screws, 2 per dial, and the "corrosion" happened around 3 of the 4 screws. It looks like the plastic expanded but never retreated to be flat again.

The part that melted is the piece between the windscreen and the rest of the cockpit. Greywolf posted a picture that very much resembles what I see on my bike. This to me is an indication that the Suzuki drive to cheap things down has finally got the better of quality. How can they, after 50 years experience, sell a motorcycle in Southern CA, an area known to get hot, with plastic so thin and cheap?

The idiot who told me the warranty doesn't apply because corrosion is not covered is NOT the dealer. Instead, this is a moron from Suzuki itself. I realized that the term corrosion really doesn't apply in my situation, but Suzuki won't acknowledge this. I have the option to take them to court or fix it myself. Since I value my time I'd rather spend the money to resolve the issue.

The windshield is not the problem unless the stock windshield that came with the bike makes the dash melt. I have a tall aftermarket windshield from Cee Bailey (which is fantastic) but my issues all occured with the original windshield mounted.

I will probably buy new dials for my gauges and install them myself. Thanks to this forum I found where I can get them with installation instructions. There are some white ones that my reflect the heat and thus preempt bubbles.

I still wonder about the other melted part. Does anybody have an idea who might make something like that out of metal so the melting issue is resolved for good. Thanks again to all who replied.
 
#14 · (Edited)
I believe the part you need is 94600-27G00
The part you listed is for the actual cowling assembly, which would not include the windshield panel.

The fiche you should be looking at is "Cowling Body Installation Parts," not "Cowling Body." 94600-27G00 is #3.
 
#17 · (Edited)
It's a single part and the warped piece in the pic is the cowling body. If I were is your shoes, I'd put a Pat Walsh Designs dash shelf on to cover the area and prevent further damage. I can't seem to reach patwalshdesigns.com right now but I found some pics.

Image


Image
 
#18 ·
Yes greywolf, unfortunately I think you are right. The part is some $205 plus shipping. I hate freaking Suzuki! I can't get this pat walsh website either ... Next time I'll buy a Harley. Chrome won't melt, I'm certain.
 
#23 ·
All years of Wees have the same cowlings.
 
#24 ·
Mind = blown.
I had no idea that a windscreen on a bike could melt the dash cowling. This is exactly what my 07 has and this whole time ive been accusing the previous owner of laying his stogies on it and melting it. I got the center of the cowl piece from another member and was going to replace mine, but now im fairly certain the new one will suffer the same fate as the old if i dont come up with a solution. A tray may be the best option, as was suggested.
I *think* i can dremmel the melted plastic off of the back of my cowl insert and get it apart, but reassembly may be an issue. I think ill try some of the plastic epoxy that comes in the double syringe from the parts stores. Ive used it before on plastic bumper covers and its done a great job.