Plastic stub on side cover broke....

[Guest]

Ok guys. I'm hoping the collective wisdom of this group can help me. I managed to break the plastic stub on the inside of my right side cover this afternoon because I wasn't patient enough and didn't think to shoot it with a little WD40 first. Fortunately, the stub broke nearly at its base, so the repair won't protrude into the rubber grommet when it's installed. It seems like something that will chemically re-bond the two pieces together, followed by something around the outside of add strength should do the trick. So..... what do y'all recommend as a product to repair this?

And when I get it fixed, is there such a thing as a permanent lubricant that I can apply to that grommet so this doesn't happen again?

As always, thanks for y'all's help.

Scott

[Redman]

I havent done it myself, but have seen many post about making a "slurry" with acetone and slivers/ground ABS plastic. Use the acetone itself as something of a solvent/glue, than apply the slurry to reinforce the post. Other folks will have to give you more specifics.

As far as the gromet, yah, some lubricant may help, but what I have done is order replacement gromets sometime when ordering other parts. That will be the more permanent fix.

Other thing I have done, is when replacing the side covers, stick fingers behind the side panel to feel the post and the groment to help align it, when have two of them aligned can feel confident in the third, then push directly where the posts are one or two at a time (not in middle of the panel).

[zuluwiz]

I have had this problem several times, including on my present bike, the Ratzuki. I clean up the areas involved, then use superglue to hold the piece in place and then mix up some epoxy and pack it in around the stem area. Put in plenty and let it harden. After it hardens, trim off the excess epoxy until the part will go thru the hole comfortably. I've never had one fail again after doing this. I know it's low tech but it works and its cheap. When I do one sidecover I usually do both just to save time. It is definitely better than buying a new sidecover and then painting to match. After all these years the plastic part are getting fragile and it is better to reach under the sidecover and push the stem out than to pull on it.

[Guest]

I have had this problem several times, including on my present bike, the Ratzuki. I clean up the areas involved, then use superglue to hold the piece in place and then mix up some epoxy and pack it in around the stem area. Put in plenty and let it harden. After it hardens, trim off the excess epoxy until the part will go thru the hole comfortably. I've never had one fail again after doing this. I know it's low tech but it works and its cheap. When I do one sidecover I usually do both just to save time. It is definitely better than buying a new sidecover and then painting to match. After all these years the plastic part are getting fragile and it is better to reach under the sidecover and push the stem out than to pull on it.

I've read the descriptions of the various types of Super Glue, and it seems like the Gel would work the best. Is that what you use? And have you ever used J-B Weld for the reinforcement? I like the fact that it gets hard enough to shape.

And yes, I have actually "reached under the side cover to push the stem out" from the backside - for this very reason. Maybe I'll remember to do it next time!

And please.... you gotta post some pictures of your "Ratzuki"!

[zuluwiz]

The superglue is there to hold the piece straight while the epoxy sets, so whatever you think is best is ok with me. I just buy whatever is cheap, same with the plastic type epoxy. It's worked every time so far.

[salty_monk]

If you need to replace one... make it flat. Get some thick aluminium angle, fashion one half into the shape of the peg and the right length. Drill several holes in the other part of the L. Stick it to the cover with Epoxy. For ultimate strength apply fibreglass over the top...

I've done 3 or 4 that way when they were missing or too short. Couple of good threads on it here somewhere...

[Guest]

If you need to replace one... make it flat. Get some thick aluminium angle, fashion one half into the shape of the peg and the right length. Drill several holes in the other part of the L. Stick it to the cover with Epoxy. For ultimate strength apply fibreglass over the top...

I've done 3 or 4 that way when they were missing or too short. Couple of good threads on it here somewhere...

Hi. Thanks for that suggestion. Fortunately, I still have the stub, so it will be a perfect fit. I'm going to use Loc-Tite Plastic Weld, as recommended by Steve Woodin.

[salty_monk]

Give it a go. Because you have a small area that you can "glue" it never worked out as a longterm fix for me that way.

These days I'd lay some plastic on the flat with my 3Doodler pen to better smooth the transition - I've done that with epoxy in the past (to create more of a dome that a flat on the end.

If I remember rightly Posplayr had a good write up on this somewhere on his 1100E build thread.

[bobgroger]

ABS Pipe cement from the plumbing section

[williamc]

Hopefully this is not too off base: I am refreshing the side cover emblems on my 1979 GS550. I purchased NOS emblems from eBay and have been frustrated with removing and installing the retaining clips (nuts). Is there a trick/tip for removing and installing these clips without breaking the posts? I have attached a photo to clearly illustrate my situation/frustration. Any help will be greatly appreciated!
gs550 Side Cover Emblem.jpg

[Guest]

Hopefully this is not too off base: I am refreshing the side cover emblems on my 1979 GS550. I purchased NOS emblems from eBay and have been frustrated with removing and installing the retaining clips (nuts). Is there a trick/tip for removing and installing these clips without breaking the posts? I have attached a photo to clearly illustrate my situation/frustration. Any help will be greatly appreciated!

I have experienced that same frustration. My solution is to GENTLY pry up one (or both) of those ears slightly with a small needle-nose pliers, while putting as little stress as possible on the post. (they will NOT unscrew, and you'll gouge or break the post trying) Once you have done that, the clip will lift off the old post easily. If you want to re-use the same clip to install the new emblem, simply squeeze the ears back into their original position BEFORE pushing it onto the post. Be sure to place a soft cloth underneath the side cover while you're doing this to avoid scratching. Hope this helps.

Scott

[williamc]

I have experienced that same frustration. My solution is to GENTLY pry up one (or both) of those ears slightly with a small needle-nose pliers, while putting as little stress as possible on the post. (they will NOT unscrew, and you'll gouge or break the post trying) Once you have done that, the clip will lift off the old post easily. If you want to re-use the same clip to install the new emblem, simply squeeze the ears back into their original position BEFORE pushing it onto the post. Be sure to place a soft cloth underneath the side cover while you're doing this to avoid scratching. Hope this helps.

Scott

Thanks! Sadly, I presumed there was no easy way to get the clips off and on. It would have been nice if Suzuki used a different method so replacing was not so difficult.

[Phred]

You can always epoxy a small rare earth magnet to the inside of the cover and install a hex bolt in the rubber grommet. There are some plastic rebuilding kits on the market as well.

[Guest]

You can always epoxy a small rare earth magnet to the inside of the cover and install a hex bolt in the rubber grommet.

That's a great idea actually! I haven't done the repair yet, and I may do the magnet thing instead. Thanks for the tip.

[Gorminrider]

You can always epoxy a small rare earth magnet to the inside of the cover and install a hex bolt in the rubber grommet. There are some plastic rebuilding kits on the market as well.

+1! ...I've used everything mentioned above including sculpting one from jbweld (it works but for how long...? and is ugly, standing off from the grommet a little)

I'm going to try this NEXT! time