Side Cover Repair

[HYPERR]

The plastic pin at the rear of the side cover that goes inside the small hole snapped off.  I have used JB Weld to repair it and all is good until I need to remove the side cover and it snaps off again every time.  Does anyone have a better solution for this?

[frankenduck]

The plastic pin at the rear of the side cover that goes inside the small hole snapped off.  I have used JB Weld to repair it and all is good until I need to remove the side cover and it snaps off again every time.  Does anyone have a better solution for this?

Easy peasy. Drill a hole where the pin used to be.  Put a piece of M4 threaded rod though the hole and then epoxy the hell out of it inside of the battery cover.  Cover the exposed part coming out of the back with heat shrink tubing.

[HYPERR]

Easy peasy. Drill a hole where the pin used to be.  Put a piece of M4 threaded rod though the hole and then epoxy the hell out of it inside of the battery cover.  Cover the exposed part coming out of the back with heat shrink tubing.

That's actually a pretty good idea.  The thing is, the side covers are otherwise in mint condition.  Is there any other way to repair it while keeping it looking stock?

[Laitch]

Any change you make according to frankenduck's instructions will only be visible if people put their eyeballs close enough to the moto to see what's in this gap. Is that what's bothering you?

[The Mighty Gryphon]

Since you have the original pin you can do what I did.

Get a 2-56x1/2" screw with a Phillips head and a flat washer.

Drill a hole in the cover that the screw will slide through and a hole in the original cover pin that you can screw the screw into.  If you have the right size drill bit the screw will go into the pin without having to thread the pin. When the pin is almost screwed all the way, put a drop of Super glue in the gap and finish tightening the screw. 

I've made this repair on 3 covers, and so far, none have failed.  If anything, the repair is stronger than the original pin.

[acyclicsalmon]

I used this product in a typical "velcro" fashion: 3M Dual Lock Reclosable Fastener 250 Black [ available on amazon ]

[jagarra]

I have used this product to make plastic repairs even building up material for missing tabs and such https://www.plastex.net/ONLINE_STORE.php

[frankenduck]

Here's a picture of a sample side cover repair. This isn't my repair. I would've used threaded rod bar stock from the hardwire store instead of these twisted solid wires, then used black heat shrink tubing on the part that sticks out. I'd also rough up the area with coarse sandpaper where epoxy is used on the inside.