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Discussion Starter #1
I purchased my KLR tail bag when I purchased my bike in 2015. The zipper no longer works to close the top cover. Has anyone come across this issue and if so how did you resolve the issue?

Has anyone found a good replacement tail bag in a soft luggage version that would come close to the KLR tail bag? If so I would sure like to hear any ideas you may have.
 

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The zipper died on my KLR handlebar bag. I really liked it so I took it to a local seamstress who put a new zipper in for me.

In the alternative, there are a few videos on YT on how to fix zippers...and I’ve had some success with that, too.

That’s if you want to keep the KLR tail bag.
 
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I have just replaced the metal widget that actually causes the zipper teeth to mesh on several broken zippers with good success. I got a package of different size closer widgets from Aerostitch.
 

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This is too common. There is a lot of gear with sub-standard zippers installed. I think the problem is that the material and labor costs are so low that installing a good YKK zipper is a cost driver.

If the product were made in the USA from genuine name-brand materials (like Cordura), then installing a YKK zipper wouldn't be a significant element of cost.

I buy YKK zipper material by the yard and sliders by the dozen. I like #5 zippers for almost everything.
 
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I've found a little bit of graphite can help maintain the zipper's functionality, but those plastic-toothed eventually seem to eventually wear out. I agree with Tom that replacing it with a "real" zipper is the only surefire cure.

I sure do feel your pain. I spend far too much time on the road playing "the zipper games"...
 

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Discussion Starter #7
Thank all of you for your great input! There is a place close to where I live I plan on talking to about replacing the zipper on the KLR trunk tail bag I have and see what they have to say. I plan on visiting my Kawasaki dealer to see what they have to say as well. Maybe they know of someone who has worked on the same sort of project.

I really do appreciate all of your input. I wasn't looking forward to paying a huge price for purchasing a new tail bag. I've been looking online and the price point for some of these tail bags are way out there in left field.
 

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Discussion Starter #8
I took my tail bag to someone today and they said the zipper was fine it's the cheap closers that were used. That said it's not a problem to fix and would have it done in a week or so. The cost to replace both the zipper closers will be faaaaaar less than purchasing a new tail bag that's for sure. I'll let you know how it turns out but the person I talked to let me know that it wouldn't be any trouble to fix. Thank goodness. I sure miss my tail bag there's no question about that!
 

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Discussion Starter #9
Sorry it took me so long to post a reply to my inquiry about rear trunk zipper repair.

So I did take my trunk to a company here in the town I live in and it took him two weeks to get around to fixing it. Not too sure I'll go there again. He did replace the "cheap" zippers with YKK zippers however the new zippers are pretty small so he put extension cords on them. I'm not all that happy with them but I'll use them until they need fixing again.

Thanks again to all who replied to my question about replacement or repairs. It's a comfort knowing I have you guys to bounce questions and ideas off of.
 
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