Side Cover with Key tab breaks Fiber Glass fix.

[Brian Donofrio]

I have two sets of side covers for my GZ250 and they both have 1 thing in common. The bottom tab is broken. A good friend showed me how to fix it with fiber glass and resin. Does anybody else have the broken tab problem?

Take a pick like a sears craftsman with a sharp tip and scratch a rubics cube pattern forming a mesh like a screen door on the parts to be re attached. The broken part always seems to remain sitting on the post that it attaches to. So it's just a matter of scratching the plastic and fiber glassing it up. Then use a Dremel to bore a hole and reinsert the rubber grommet and your back in business!

[5th_bike]

Originally Posted by Brian Donofrio

I have two sets of side covers for my GZ250 and they both have 1 thing in common. The bottom tab is broken. A good friend showed me how to fix it with fiber glass and resin. Does anybody else have the broken tab problem?

No, but the side covers are tricky indeed, the left one's bottom tab goes straight up and the right one's bottom tab goes straight out to the right side.

When I bought my bike the left cover had a big crack in it, so I replaced it.

[Easy Rider]

Originally Posted by 5th_bike

No, but the side covers are tricky indeed, ......

We're talking about the posts that pop into a large rubber gromet, right ??

Those are easier to deal with and MUCH less likely to break from "normal" use if you put some silicone lube around the inside of the gromet. SILICONE only as other lubes tend to damage the rubber or plastic (or both) and make the situation worse instead of better.

[5th_bike]

Originally Posted by Easy Rider

We're talking about the posts that pop into a large rubber gromet, right ??

I think that Brian was talking about the bottom tab of the left cover. It is the only one that "remains sitting on its post" after it is broken off.
It just slides up off its post, whereas the three other posts are attached to the side covers (1 left top, 2 right - top and bottom) they are the horizontal pop-type.

Thank you for the silicone lube tip, next time around when doing something like checking the air fiter, oiling the lock cable, checking the battery (posts) - I'll try to remember and lube the 'pop' grommets and posts.