Repairing cracked/broken shrouds on the 08 klr - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 5 Old 04-02-2008, 06:33 PM Thread Starter
Join Date: Mar 2008
Location: Richmond, KY
Posts: 9
Repairing cracked/broken shrouds on the 08 klr

Ok, like a large number of us, I have discovered that the shrouds on the
'08 KLR's are pretty brittle and prone to breakage. I found a good way to fix these with I will pass on. Bear in mind this is functional in nature and not necessarily the prettiest.

First, you are going to do all of the repairs on the inside of the shroud. Realign the cracked pieces and use thin Super Glue to hold them in place. Do the same for any small pieces which are broken off. I find that the "thin" SG works best as it will usually draw into the cracks via capillary action. The best "thin" SG can be purchased at any hobby store which caters to radio controlled cars/planes. I also use an accelerant to quick set the SG. This is also available at the hobby shops.

Second, you will need some fiberglass cloth, Gorilla Glue and disposable rubber gloves. The gloves will keep the glue off your hands. You can get the fiberglass cloth at any auto parts store. The Gorilla Glue at Wally World, Lowe's etc.

Third, cut pieces of the fiberglass cloth, about 2x2" and 1x2". Work in small areas about the size of the pieces of cloth. Start by covering an area the size of a piece of cloth with the Gorilla glue. Place the cloth down on the glued patch, overlapping both sides of the crack or break. Press the cloth down saturating it in the glue. It need be, add some more glue to saturate the cloth. You'll know you have enough when the cloth turns the color of the glue instead of white.

Fourth, keep adding glue and pieces until you get the entire crack/break covered. In areas of higher stress, like corners or the locator post, add more than one layer of the cloth and glue.

This will all set up over night. When it is hard you can trim off any stray strands of fiberglass.

Gorilla glue bubbles up as it cures, but if you "welded" the pieces first with SG it should not bubble through to the finished side.
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post #2 of 5 Old 04-02-2008, 08:01 PM
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Join Date: Oct 2006
Location: Evansville, Indiana
Posts: 815
WOW.... how many has this been now? Compared to how many pre08 panels? I knew all that plastic was nothing but trouble.
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post #3 of 5 Old 04-02-2008, 08:53 PM Thread Starter
Join Date: Mar 2008
Location: Richmond, KY
Posts: 9
If I can find some large enough sheets of Kydex plastic, I am going to try making replacement shrouds from that. Kydex is the material used in knife sheaths and military pistol holsters. While it retains some flexibility, it is virtually unbreakable. This could be the solution to our problems, unless one of the companies who make tanks and fenders can make them out of their poly based plastic.
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post #4 of 5 Old 04-02-2008, 08:58 PM
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Join Date: May 2007
Location: Richmond, Ky
Posts: 1,980
Now that would be a sweet deal. Another friend of mine that has an 08 has already replaced BOTH sides. Has less than 300 miles on the bike, and both instances were from MILD contact with objects in his garage.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #5 of 5 Old 04-02-2008, 10:20 PM
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Join Date: Nov 2007
Location: Corpus Christi, TX
Posts: 704
While I seriously dislike kydex holsters (just old school, I guess) it would seem to be great underlayment since it can be easily heat formed and does have a little flexibility when a "give" is needed.

I'm interested in the longterm performance of the Gorilla Glue, since it is moisture activated, needs to penetrate surfaces to adhere well and has little or no flexibility after cure. Not dissing it - just curious - it's great for it's purpose. And I don't have an alternative to offer unless it would be a material specific adhesive or welding.
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