Lost a side panel - Kawasaki KLR 650 Forum
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post #1 of 4 Old 05-19-2008, 12:12 PM Thread Starter
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Join Date: Apr 2008
Location: Harker Heights, TX
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Lost a side panel

So a few weeks ago I took everything off the bike to prep it all for paint. Spent a week or so prepping and painting my Kawasaki greeen KLR flat black with a reflective clear coat.

I went on a ride Saturday to wring it all out and she rode great!!!

Rode to work today and my left side panel had fallen off somwhere between home and work, I went around the bike to look at the rest of the panels and two of the three screws holding the right side rad shroud fell out as well.

Now I loctited EVERY SINGLE screw or bolt when I put it all back together .

So aside from the general post I am also looking for a left side panel and some ideas on where I can find replacement screws? Color doesn't matter since I'm gonna paint it anyway, but I can't get on ebay from work.

Thanks,

CPTD

2006 Orange Reflective KLR, T-mod, Stebel, Hurricane mod, home-made racks and cases, Tusk hand guards, .22 cent smile maker, Cee Bailey's 4 over, and a bunch of other stuff!
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post #2 of 4 Old 05-19-2008, 12:54 PM
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We used 10.9 hardness bolts with the same size head that holds the seat on. That way a 10mm socket is all that is needed to remove most everything in that area. Unless someone in here has an extra set of side panels, EBay seems to be the place to find one. Would like to see some pics of the paint job when you get it finished up.. I think this winter, we are going to tear my 07 down and paint the frame, forks, and swing arm in Satin Black.

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 #3 of 4 Old 05-20-2008, 08:18 AM
 
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Quote:
Originally Posted by cptd View Post
So a few weeks ago I took everything off the bike to prep it all for paint. Spent a week or so prepping and painting my Kawasaki greeen KLR flat black with a reflective clear coat.

I went on a ride Saturday to wring it all out and she rode great!!!

Rode to work today and my left side panel had fallen off somwhere between home and work, I went around the bike to look at the rest of the panels and two of the three screws holding the right side rad shroud fell out as well.

Now I loctited EVERY SINGLE screw or bolt when I put it all back together .

So aside from the general post I am also looking for a left side panel and some ideas on where I can find replacement screws? Color doesn't matter since I'm gonna paint it anyway, but I can't get on ebay from work.

Thanks,

CPTD
What type of paint did you use for the plastic? My panels are all dorked up, scratched gouged etc and would love to get them looking less - pink...from the sun. (supposed to be red!)

Thanks!

Sean
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post #4 of 4 Old 05-20-2008, 09:24 AM Thread Starter
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I found a rust-o-leum universal paint at Home depot that had a trigger built in. It worked well but the trigger device kinda sucked, and ended up putting drips all over the place because of paint buildup in the trigger mech. If I did it again I would just get a plastic spray paint with a traditional button and use my trigger that clips on to the can. Krylon Fusion (at Wal-mart) works well, and so does Valspar Plastic (at Lowes) both are cheaper than what I used. I would think seriously about using duplicolor bed liner, then a quick shot of whatever color I wanted if black was not it. That stuff is supposed to work well on plastic and it is pretty durable. Seems to flex with the plastic and not scratch easily.

The reflective stuff makes the bike look like it is covered in white pollen until you flash some light at it, mostly at night, then the whole bike turns white. If you are looking for a professional looking glossy finish it will not work, but if you don't mind the dusty matte look then it is pretty cool. I think if I did it again I would not paint he whole bike with the reflective stuff, only key locations for visibility.

The key to success is prepping the plastic. Clean it all with a good degreaser, I used simple green and HOT water. Then I sanded with steel wool and super fine sandpaper, then rubbed it all down with Acetone to get rid of any buildup.

I was not concerned with a glossy finish at all so I didn't care if some dust fell into the wet paint, I knew I was going to cover it all with the dusty looking reflective. If you want gloss then you have to be anal about contaminates in the air around your work area.

I used the same paint on the metal tank that I used on the plastic. Made it really easy to go from piece to piece. I did three coats on everything and by the time I got to the final pieces the first ones were dry enough for another coat. All in all it took about 3 hours to prep and less than 2 to paint everything black, and another hour to paint the reflective.

I'll do another thread this weekend with pics in the sun and at night. It has been raining here so I haven't been able to get the bike out in the yard except yesterday to go to work when I lost the panel.

CPTD

2006 Orange Reflective KLR, T-mod, Stebel, Hurricane mod, home-made racks and cases, Tusk hand guards, .22 cent smile maker, Cee Bailey's 4 over, and a bunch of other stuff!
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