Join Date: Nov 2012
Location: Elyria, OH, USA
Re: Plastic repairs - Plastex or JB Weld?
I have experience with exactly the same break on my newly-purchased 2003. Seems that this is one of the weak links of the bike, caused either by overloading the small rack on the top case lid, or by letting the lid 'overextend' itself while opening.
I was fortunate enough to have the hinge break cleanly. Though it was very ugly, and a couple of small pieces fell into the trunk body, the remainder was a good, clean fit back together.
Short answer is that I took a Dremel and and ground off the lower rivets, which separated the hinge from the trunk body, so I could work with just the plastic. Called the very helpful people at JB to confirm that this glue would be appropriate for the repair. Was answered in the affirmative, but the tech made it VERY CLEAR that 90% of adhesion failures were due to improper preparation of the parts to be glued. Couldn't stress enough that the parts were NOT to be cleaned with alcohol, as it leaves a residue which weakens the bond. Follow the directions and you'll be fine.
Just a note: In order to prevent hyper-extension of the lid in the future, I went to the local sporting goods store, bought a piece of 16" or 18" (I forget which) stainless cable fishing leader (30# test) and attached it along side the nylon trunk strap. Folds easily upon itself, and prevents the top from opening too wide.
The whole repair looks good and has held beautifully.
"A severed foot is the ultimate stocking stuffer."
BMW K1200LT "Carpathia"
Suzuki GV1400 Cavalcade "Paladin"
Kawasaki ZX14 Ninja "Shashka"
Kawasaki GPz1100 "Sicarius"
Buell S3 "Pazuzu"
Honda GL1100 Gold Wing "Aurore"
Honda PC800 Pacific Coast "Octavia"
Honda CB750F "Genvieve"
And other remnants of a misspent youth.