Tenere 700: Repair of Broken U-Nut Tabs on Body Panel

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 Repair of Broken U-Nut Tabs on Body Panel

The T7 ABS body panels bolt mounting tabs that hold the U-nuts in place are not designed to withstand much torque or stress & can snap off easily if misaligned and/or over tightened. 

Tech Tip: ensure that body panels are fully aligned in place & hand tighten snug, additional tightening & use of loctite not recommended as the torque required may exceed the tensile strength of the tabs.


Repair

Plastic welding/soldering could be used for this type of repair, however, I opted to use RapidFix to chemically bond 1.5 mm (1/16") black abs to the back of the tabs & a smaller piece inserted into the void on the front where the tab with the bolt hole broke off. The thickness of the 2 bonded pieces is a little more than tab's 2.6 mm (3/32") thickness & the slightly recessed slot for the spring nut.


Tech Tip: lightly scuff up the surfaces to be bonded with sand paper & clean thoroughly with Isopropyl alcohol (99%)


I used a much stronger BMW U-nut #46-63-7-658-638 I had left over from my K1300GT vs the smaller & lighter duty Yamaha #90183-05076 U-nut, which have a tendency to split apart, both with the same thread size & pitch.

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