GS550e side covers...solution?

[Anonymous]

I think this has been posted before, but I can't seem to find it. I have an 85gs550e and both plastic side covers have broken tabs. One cover is held on with duct tape and the other is hanging on for dear life! Does anyone have a solution to this other than finding new covers?

[Anonymous]

Oy,

Do you still have the pegs? The ones that attach the fairings to the frame, the ones that keep breaking off?

I had the same problem, I used every gunk and adhesive in the market to glue those silly nubs to the inside of the fairings. Finally I used 5 minute epoxy and that has held so far (about 2 years now). The 5 minute worked well because since it hardens faster you can really build it up. The "harder" but slower 24 hour epoxy spreads is self out over the 24 hours and would no build up big enough to make it INDESTRUCTABLE!

If not, you need more duct tape

[Anonymous]

So did you just pile it on and shove the tabs in the holes, then hold it for a few minutes? Thanks again!

[Anonymous]

I believe that many of us have had this side-cover problem over the years. You can make a durable fix without too much difficulty, if you still have the pegs/tabs.

There are many methods possible. Mine is to use a 2-part epoxy called "Plastic Welder", to be found in most hardware stores. First, I drill a small hole through the broken peg, and insert a piece of cotter pin (aka split pin) through the hole with equal lengths showing both sides. I then bend the pin back so that, when the peg is replaced, the bent pin reaches back along the peg and then lies along the inside surface of the side-cover.

The next step is to score (with a razor blade) and dimple (with a small drill bit) both the peg's and side-cover's surface where the epoxy will be applied. Mix up a small amount of the Plastic Welder and apply to the replaced peg and cotter pin to hold them in place on the side-cover. After a little while, you can mix up a bigger batch of the epoxy to build up a sturdy support. You have to work fast after mixing the Plastic Welder because it is quite stiff to begin with, and sets up even stiffer in a few minutes.

Other epoxies can be chosen but, in my opinion, Plastic Welder is the best. It has about the highest strength of all the epoxies and its consistency and quick cure time are big advantages for this kind of job. BTW, the purpose of the cotter pin is to increase tensile strength, useful when the cover is pulled off the bike in normal use.

I fixed my broken sidecover pegs over 20 years ago, and haven't had to worry about them since. The fix is stronger than the original part.

Simon

[Anonymous]

I reattached the rear mounting peg on the side cover of my 550L using West System Marine epoxy and short strips of fiberglass reinforcing tape. I had a problem holding the peg in place until the epoxy started to harden. The repair is very durable.

[Anonymous]

mikdes,

There are other great ideas here, I'm just replying because of your question.

No, I would not recomend "pile[ing] it on and shove the tabs in the holes" that would glue the pegs and the fairings to the frame. I would pile it on and hold it in place away from the bike.

Not sure if that was what you meant, but I just did not want you to stik the entire thing to the bike and never be able to get to your fuses of battery.

[QuaiChangKane]

My side panels are drilled through, and secured to the mounting holes with clip nuts (blind nuts).

The nuts are basically a piece of bent spring steel with a hole through them (almost like auto door panel clips) - take the rubber grommets out of the frame tabs that normally secure the side panel pins and slip the clip nuts over them. Drill the panel completely through where the plastic pins used to be. Get some coarse thread screws (1/4") long enough to hold the panels in place, and some rubber washers to put on the screw behind the panel so you can't over-tighten the screws.

The screws can be painted to match your bike, and you'll never have to worry about poxy failing and your tabs breaking off on the freeway...

I know it's a vague description - PM me and I can email you some pictures.


-Q!

[jimcor]

This time I'm being serious (yer, kiddin', right?). The regular JBWeld will hold those pegs on. Epoxy the first time just to peg them down. Wait at least 24 hours and then build up a 'mound' of the stuff around the peg. Wait 48 hours befor applying heavy pressure. It worked for me where the quickie plastic cements and miracle glues did not. Now, I must be off, have a great weekend everybody!

[QuaiChangKane]

I'm not so leery of poxy or JB Weld failing as I am of the plastic tabs that broke once breaking again right next to the repair....

The screws are a snap, and I'm through worrying about it.


-Q!