My Pulse when I got it shows evidence of having been dropped, as the foot brake side panel was cracked in three places, the front mudguard cracked near the mounting bolts on the headlamp fairing scuffed. Now no way am I purchasing new plastics until at least I have had a go at repairing them, so I set about how to repair.

Well the side panel, that was the biggest issue, I sort of worked out the thing was made from a styrene based plastic by noticing the smell when heat was applied, I also noticed when applying the heat with a soldering iron the stuff melted so I effectively stitched the cracks back together by melting the plastic on either side of the crack on both sides of the panel and then filled the outside crack with fine body filler after smoothing down any rough bits. The result is satisfactory, I have not flexed the panel greatly to ascertain strength, but I believe the strength to be good enough for normal use.

I also noticed high strength cyanoacrylate glue ( super glue) is also effective on these plastics, but the thought has occurred to try and replicate the panels in a more durable plastic, glass fibre even as that is achievable with a modest home set up, or reinforce the stock plastics on the underside.

As the stock plastics seem to be a little fragile, has anyone tried to replicate the standard bike plastics in a more durable material ?