Seat Pan Rehabilitation

[mswyka]

Show me a Kawasaki seat pan in perfect condition and I would wager that I could show you a sled that has never been ridden.  As a matter of fact, I have yet to see a seat pan that didn't need some degree of repair.  We have found that the seat pan plastic responds nicely to the same PVC solvent that you would use to connect PVC pipe.  We cannibalize a badly damaged pan and use the parts to reinforce cracked or broken parts of other pans - usually the corners and mounting points.

We have two seats in process in the shop right now so I thought it would be a good time for a photo.

Once rehabbed for the front attachment we add a strip of plywood and new stainless steel "tee" nuts.  In the rear we change the attachment point and drill new holes through the glove box hinges and then use a stainless 1/4 - 20 x 1 bolt and nylon lock nut in each hinge. 

[mswyka]

Thought I would  add a few photos of the next steps.  This is the plywood block added at the front corners of the pan.  It is held in place initially with the 1/4-20 bolt.  Then the extra long 3/16 blind rivets are added.

[gixxer6]

Nicely done. 

[ewachk]

What I have done with mine is shape a peice of aluminum and rivet it over the plastic. Then install a spreadable nut anchor through the aluminum. Should prevent the plastic from busting up again.

[mswyka]

What I have done with mine is shape a peice of aluminum and rivet it over the plastic. Then install a spreadable nut anchor through the aluminum. Should prevent the plastic from busting up again.

I would be interested to see a photo.

[ewachk]

And I would gladly give you one but I just installed the seat cover last week and never took any pics. I could show you the spreadable nuts that I used. I have some leftover.