Side cover repair
- kzz1king
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Re: Side cover repair
16 Jun 2013 22:37
The Kawasaki Concours 86-2005 have a lot of plastic on them and they are made of ABS. Drywall mesh,ABS cement and ABS shavings if you need to make some repair material are what most use. Try googling Concours fairing repair or something. I used drywall mesh and JB on all of my cracks and brocken off tabs and had no failures, Someday I will try the ABS route because it is supposed to work well.
Wayne
Wayne
74 Z1 1075, 29 smoothbores, owned and ridden since 1976
Home built KZ1000 turbo setup
www.kzrider.com/forum/11-projects/532476...s-budget-turbo-build
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Home built KZ1000 turbo setup
www.kzrider.com/forum/11-projects/532476...s-budget-turbo-build
www.kzrider.com/forum/11-projects/532489-74-z-makeover
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- Godfrey
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Re: Side cover repair
16 Jun 2013 22:52
I have used the plastex product with good results on both my side covers and where the break was is actually stronger then stock.
1981 650CSR frame
1980 KZ750E engine
1980 KZ750E engine
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- bluej58
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Re: Side cover repair
17 Jun 2013 09:36
If you plan on using a mesh I would go with the true auto body stuff instead of using a drywall tape.
I have seen different types of drywall tape get brittle and tear or fall apart over time.
JD
I have seen different types of drywall tape get brittle and tear or fall apart over time.
JD
78 KZ1000 A2A
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- 650ed
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Re: Side cover repair
17 Jun 2013 10:14
Take a look at this link for replacing side cover tabs; it contains an interesting approach that looks like it works well. Ed
forums.kz650.info/index.php?topic=9730.0
forums.kz650.info/index.php?topic=9730.0
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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- KZJOE900
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Re: Side cover repair
17 Jun 2013 11:04 - 17 Jun 2013 11:05650ed wrote: Take a look at this link for replacing side cover tabs; it contains an interesting approach that looks like it works well. Ed
forums.kz650.info/index.php?topic=9730.0
Great post Ed! The only thing I wonder about is the cost of the material the gentleman used to make the post. I would take a guess at $50.00. At that point, I think it becomes a situation of diminishing returns. Would it be wiser just to invest the $50.00 in a used replacement cover? I don't know. On the other hand, if the material has a long shelf life, it can come in handy for other applications or restorations. The guys did an incredible job on the part. Gotta take my hat off to him. Very good knowledge to have. Now, if he can only show how to reproduce the whole cover :laugh: That would be even more awesome.
Current project 76 KZ900 (This was a Vetter model)
76 KZ900
81 XJ550H SECA (Current Project)
82 XJ550R SECA
Past:
86 FJ1200
74 Z1900
72 CB450
76 KZ900
81 XJ550H SECA (Current Project)
82 XJ550R SECA
Past:
86 FJ1200
74 Z1900
72 CB450
Last edit: 17 Jun 2013 11:05 by KZJOE900.
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- KZJOE900
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Re: Side cover repair
17 Jun 2013 11:14 - 17 Jun 2013 11:28
Here is what I'm going to attempt to repair. I plan on using the Permatex Plastic Weld or the Loctite Plastic Bonder (both are about $6.00) along with a fiberglass backing. I know it looks crazy to even attempt to fix this. But these panels are very rare and would cost me $100 plus to get a used replacement, $200.00 for the set. Plan on fixing this one and biting the bullet and purchasing the right panel.
Current project 76 KZ900 (This was a Vetter model)
76 KZ900
81 XJ550H SECA (Current Project)
82 XJ550R SECA
Past:
86 FJ1200
74 Z1900
72 CB450
76 KZ900
81 XJ550H SECA (Current Project)
82 XJ550R SECA
Past:
86 FJ1200
74 Z1900
72 CB450
Last edit: 17 Jun 2013 11:28 by KZJOE900.
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- 650ed
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Re: Side cover repair
17 Jun 2013 11:48 - 17 Jun 2013 11:51
I see you have an entirely different situation you're dealing with, not just a pin snapped off. Have you tried contacting an automotive paint supply store? I had a car with a broken air dam made of some weird plastic that needed repair. I went to an automotive paint supply store (Mattos) and they had a kit that included backing material and the resin stuff to repair it. They had different kits for different types of plastic. As I recall it was inexpensive. That was 18 years ago and the repair has never failed since. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Last edit: 17 Jun 2013 11:51 by 650ed.
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- ed spangler
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- Tennessee Z
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Re: Side cover repair
17 Jun 2013 12:30
theres a GREAT Tech/how to article on this web site , just for things like this, I read it, and DID IT!! Worked good. Check it out in Technical section / archives or ask Patton, tennesseeZ ED
Have 1975 Kawasaki Z1-B & 2003 Harley Davidson Heritage Softail Classic
Had Hondas, Harleys and many ,many Z Series Kaws both Std. & LTD's
Had Hondas, Harleys and many ,many Z Series Kaws both Std. & LTD's
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- KZQ
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Re: Side cover repair
17 Jun 2013 13:42ed spangler wrote: theres a GREAT Tech/how to article on this web site , just for things like this, I read it, and DID IT!! Worked good. Check it out in Technical section / archives or ask Patton, tennesseeZ ED
I couldn't find it Ed. Could you post a link to it?
Bill
www.KZ1300.com
Riders:
1968 BSA 441 Shooting Star, 1970 BSA 650 Lightning, 1974 W3, 1976 KZ900, 1979 KZ750 Twin, 1979 KZ750 Twin Trike, 1981 KZ1300, 1982 KZ1100 Spectre, 2000 Valkyrie, 2009 Yamaha Roadliner S. 1983 GL 1100
Projects:
1985 ZN1300
Riders:
1968 BSA 441 Shooting Star, 1970 BSA 650 Lightning, 1974 W3, 1976 KZ900, 1979 KZ750 Twin, 1979 KZ750 Twin Trike, 1981 KZ1300, 1982 KZ1100 Spectre, 2000 Valkyrie, 2009 Yamaha Roadliner S. 1983 GL 1100
Projects:
1985 ZN1300
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- bluej58
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- ed spangler
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- Tennessee Z
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Re: Side cover repair
17 Jun 2013 16:45KZCSI wrote:ed spangler wrote: theres a GREAT Tech/how to article on this web site , just for things like this, I read it, and DID IT!! Worked good. Check it out in Technical section / archives or ask Patton, tennesseeZ ED
I couldn't find it Ed. Could you post a link to it?
Bill
Hello Bill
It had been at least 2 years since I accessed it, Read it and used the techniques in it, It was best I recall relatively simple and inexpensive, I just now went and looked for it, didnt see it,

TennesseeZ Ed
Have 1975 Kawasaki Z1-B & 2003 Harley Davidson Heritage Softail Classic
Had Hondas, Harleys and many ,many Z Series Kaws both Std. & LTD's
Had Hondas, Harleys and many ,many Z Series Kaws both Std. & LTD's
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- Grumpy Ole Artist
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Re: Side cover repair
02 Apr 2014 12:16
Sorry for bumping an old thread, but I just fixed my side cover with acetone and abs slivers...let it dissolve overnight and pow! instant ABS putty...the ABS pipe has been discontinued along with the glue!
1978 KZ650 B2
Former rides...1976 CB360T, 1985 Shadow 700, 1985 GPZ750Turbo
Former rides...1976 CB360T, 1985 Shadow 700, 1985 GPZ750Turbo
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