Broken side cover mount - Kawasaki Versys Forum
 
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post #1 of 12 (permalink) Old 04-14-2009, 06:17 AM Thread Starter
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Broken side cover mount

My headlight needed adjustment which requires the removal of the left and right side covers. First I took off the right side without any problem. Then, on the left side, the moulded protrustion that snaps into the chassis broke off. I did not pry the cover in any way that would have caused it to break.

This was the first time the covers were removed.

Has anyone experienced this and did the warranty cover a replacement cover?

Any idea if the broken piece can be glued back onÉ

thanks
Woody
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post #2 of 12 (permalink) Old 04-14-2009, 06:35 AM
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Is it a warranty item? Can't hurt to ask.

If the parts still mate reasonably well, I'd get some fast set epoxy and bond them with as little excess epoxy as possible. Let the repair sit a good long time so it's fully cured, then always keep it and the rubber grommet it mates with well lubed so it slides on and off with minimal stress.


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post #3 of 12 (permalink) Old 04-14-2009, 10:00 AM
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I know this is too little, too late, but you don't actually have to remove the side covers to adjust the headlight. You can just reach up under the "dash" and turn the screws by hand. It takes a bit of searching, but I've done it several times now trying to dial in the headlight.
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post #4 of 12 (permalink) Old 04-14-2009, 05:56 PM
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I could fix it with a hot glue gun... Where about are you, BigWoody? Welcome to the forum.

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post #5 of 12 (permalink) Old 04-14-2009, 07:13 PM Thread Starter
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I'm in Ontario Canada Invader. Do you think glue gun glue would be strong enough?

BigWoody
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post #6 of 12 (permalink) Old 04-14-2009, 07:52 PM
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three bond sells a plastic repair kit that almost any dealer can get for you. comes with a glue, fiberglass mesh and quick set activator. takes about 3 minutes to set up once you spray the activator on the wet fiberglass mesh. I've used it for snowmobile hoods with good luck.
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post #7 of 12 (permalink) Old 04-14-2009, 08:10 PM
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The same thing happened to me last year when I was "working" on the bike in a state of inebriated ineptitude. Crazy glue made it all well again. I doubt you could make a warranty claim out of it, in your case.
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post #8 of 12 (permalink) Old 04-14-2009, 09:02 PM
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Quote:
Originally Posted by BigWoody View Post
I'm in Ontario Canada Invader. Do you think glue gun glue would be strong enough?

BigWoody
I would use the hot gun to weld it back together, with some heavy duty gun glue mixed in. I can even rebuild large holes or missing sections on plastic parts... Where about in Ontario?
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post #9 of 12 (permalink) Old 04-14-2009, 11:02 PM
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I've used Plastex many times with great success.
http://www.plastex.ca/
J.
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post #10 of 12 (permalink) Old 04-15-2009, 07:04 AM Thread Starter
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Invader, I'm in Georgetown (just outside Mississauga/Brampton area).
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post #11 of 12 (permalink) Old 04-18-2009, 12:27 PM
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I had similar problems with my current Kawi bike (not a V). The fairings were cracking out at the mounting screws. Screws were not overtensioned and I showed the dealer, who sent pics to Kawi. Kawi said: no warranty work.
I fixed the fairings from the reverse side by adding and molding epoxy putty and the redrilling and repainting. Looks OK but IMO the plastic fairings were of poor quality.
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post #12 of 12 (permalink) Old 04-19-2009, 12:30 AM
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You can ask, but I doubt Kawasaki will replace it.

It's not a critical part, your side cover will stay on just fine without it. It may have a slightly larger gap on that side it you don't manage to glue it back on, but that is about it.

Gustavo


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