How to repair broken left side cover lug?

[yechave]

This is the small pastic cover with the center stand handle going through it. I have taken this off before, but it snapped this morning. (99 R1100RT)

 

I drilled a hole and put an electric tie on to hold the cover for now. What is the fix for this problem, other than to replace the cover? There has to be a better way.

 

Seems like poor system/fit to bike, to start with.

 

I was attempting to match up the battery charger port, which was poorly attached to the frame. Really did not care to be fixing or altering anything else before the trip coming up in just a few days.

 

Appreciate the advice. Thanks!

[Boffin]

There is a walkthrough of a very good repair using plastex available through the M/C FAQ at the top of the page. I just drilled a hole in the end of the broken off peg, another in the place from where it broke, then used a self-tapping screw with a hex-head to refit it. The hex head just made it easy to hold the screw still whilst turning the peg.

 

HTH,

 

Andy

 

edit: BTW, the left-hand panel will stay in place for years without the peg. I did however, lose the right-hand panel somewhere in South-West England when it detached itself on a ride.

[AndyS]

Seems like poor system/fit to bike, to start with.

 

Well yes! and now for sure you join the ranks of what must be thousands of lugless side panel owners

[Fugu]

I drilled some little holes around the base of the lug, and a couple through it.

 

Glued it back in place w/ Pascofix (cyanoacrylate glue) and a little of their filling powder stuff that makes it set up fast.

 

Then I made a little masking tape form around the base, filled it with thin epoxy, making sure to work it into the little holes I drilled.

 

It's stronger than it was before.

[SWB]

Seems like poor system/fit to bike, to start with.

 

Well yes! and now for sure you join the ranks of what must be thousands of lugless side panel owners

 

You mean there's supposed to be a peg to go in that grommet on those panels? Sheesh.. who knew? I just through BMW hired a 70's US automotive engineer to design that rattlely, break-prone piece of work.

[yechave]

I had to fix the damn thing. At least I know a little more about the bike.

 

I drilled out the panel, put an inside threaded piece (don't have any pics) inside the gromet and used a 1/4-20, large headed brass screw on from the outside. Use a coin to remove. Will last longer than I do.

 

Hoping the other side continues to function with the plastic lug, at least until I dial in the rear shock adjustment.

 

Took off all the bags just to see what a difference that made..... surprised to find it all weighed in at 62lbs, half loaded. Bike did not ride well without them however.

 

Had to remove the previous owner's over-sized side stand plate. Was proving to be too much with a passenger onboard trying to put it up and down. One too many close calls almost dumping the bike because of it.

 

I think a Russell seat will solve the remaining issue. If not, might have to look for something else.

[mrduck]

Ya know, just a small finger wipe of grease on those lugs might keep that stuff from happening!

 

My cheap advice for the day.

 

 

 

[yechave]

Just did the grease wipe last week. I think had I removed the luggage first, it would not have happened. I was under the impression that was not necessary.

 

One of the guys at the dealership has a 99 since new, and he broke his off as well, and he knew better. I've only had the bike for three weeks.

 

Also found the plastic thingies at the bottom of the side plates are shot as well. Is that a dealer item or buy on the web?

[Fugu]

Ya know, just a small finger wipe of grease on those lugs might keep that stuff from happening!

 

Not the way I busted mine. I was being extra special ham fisted that day.

[Seeker130]

Design flaw if you ask me.

I don't worry about it.

The cover is still there.