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Editor’s Top Picks (Skip to buying)
Best plastic weld kit
Master Appliance HG-501A Heat Gun
Best fiberglass kit
Bondo Fiberglass Repair Kit
Best paint touch-up
Dupli-Color Perfect Match Motorcycle Paint
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Motorcycle body components + damage
Fairings (plastic body panels)
- Most common damage type
- Prices: $150-$1,500 per fairing (varies by model)
- DIY plastic welding: $30-$50 in materials
Fuel tank
- Metal tanks: dent removal + repaint required after damage
- Plastic tanks (KLR, dual-sport): plastic weld + fuel-resistant repair
- Prices: $250-$1,500 (used) or $1,500-$4,500 (new)
Windshield / windscreen
- Prone to rock damage + crash damage
- $100-$450 replacement
- Some universal fitments work across models
Seat + subframe
- Post-crash damage from ejection or impact
- $200-$800 for seat, $400-$1,500 for subframe
Handlebars + controls
- Bent handlebars: $50-$250 replacement
- Broken levers, mirrors: $30-$200 per part
DIY fairing repair
Cracked plastic fairing (most common)
- Clean cracked area with isopropyl alcohol
- Identify plastic type (usually PP or ABS)
- V-groove crack with rotary tool + burr
- Match plastic welding rod to fairing material
- Melt rod into crack with heat gun
- Smooth with plastic spatula
- Sand smooth (180 then 220 grit)
- Paint match with model-specific paint
Time + cost:
- DIY: $30-$60 for plastic weld + paint. 2-3 hours.
- Shop: $250-$650 per fairing.
DIY tank dent removal
PDR method for tank dents
- Access from behind tank (remove seat, fuel line)
- Use PDR push tools to press out from inside
- Or use suction cup method for shallow dents
- Repaint tank with model-matched color
Warning about tanks:
- Metal tanks need thorough drying after repair (moisture = rust)
- Plastic tanks can’t be welded without special fuel-resistant welding rod
- Damaged tank seals cause fuel leaks — safety hazard
Insurance for motorcycle body damage
- Collision + comprehensive coverage handles crash + non-crash damage
- Deductibles typically $500-$1,500 (higher than car policies)
- Older motorcycles often not worth full comprehensive coverage
- Custom motorcycles require agreed-value policies
Post-crash checklist
- Get to safety, don’t touch damaged bike
- Call 911 if injured
- Photograph damage extensively
- Move bike out of roadway if possible
- Contact insurance immediately
- Get medical checked (injuries appear delayed)
- File police report for insurance claim
When to skip DIY on motorcycles
- Frame damage (safety-critical)
- Fuel tank leaks
- Electrical system damage
- Wheels or hub damage
- Anything requiring welding on structural components
Best products for this scenario
Best plastic welder
Master Appliance HG-501A Heat Gun
Professional-grade heat gun for motorcycle fairing welding. Precise temperature control.
Motorcycle body components + damageFairings (plastic body panels)Fuel tankWindshield / windscreenSeat + subframeHandlebars + controlsDIY fairing repairCracked plastic fairing (most common)Time + cost:DIY tank dent removalPDR method for tank dentsWarning about tanks:Insurance for motorcycle body damagePost-crash checklistWhen to skip DIY on motorcyclesBest products for this scenarioMaster Appliance HG-501A Heat GunBondo Fiberglass Repair KitDupli-Color Perfect Match Motorcycle PaintUniversal Plastic Welding Rod KitUshylynn Complete Plastic Weld KitMotion Pro Motorcycle Tool Kit3M Panel Bond Structural AdhesiveFAQCan I repair a cracked motorcycle fairing myself?How much does motorcycle body damage cost?Does motorcycle insurance cover body damage?Can I paint over motorcycle plastic repair?What plastic type are motorcycle fairings?How long does motorcycle body repair take?Bottom line
Best fiberglass repair kit
Bondo Fiberglass Repair Kit
For cracks and holes in motorcycle plastic panels. Structural strength.
Check Price on Amazon →Best motorcycle-specific paint
Dupli-Color Perfect Match Motorcycle Paint
Manufacturer-matched aerosol paint for motorcycle body work.
Check Price on Amazon →Best plastic welding rods
Universal Plastic Welding Rod Kit
PP + ABS + PC welding rods for various motorcycle plastic types.
Check Price on Amazon →Best DIY starter kit
Ushylynn Complete Plastic Weld Kit
Everything needed for motorcycle fairing repair. Heat gun + rods + safety gear.
Check Price on Amazon →Best motorcycle-specific tools
Motion Pro Motorcycle Tool Kit
Motorcycle-specific tool set. Compatible with major brands (Honda, Yamaha, Kawasaki).
Check Price on Amazon →Best plastic adhesive
3M Panel Bond Structural Adhesive
For structural motorcycle panel repairs without heat. Fast setting.
Check Price on Amazon →FAQ
Can I repair a cracked motorcycle fairing myself?
Yes with plastic weld kit or structural adhesive. Save $250-$650 vs. shop replacement.
How much does motorcycle body damage cost?
Fairings: $150-$1,500 per side. Tanks: $250-$1,500. Windshields: $100-$450. Full crash repair: $2,000-$8,000+.
Does motorcycle insurance cover body damage?
Collision + comprehensive coverage yes. Deductibles typically higher than car policies ($500-$1,500).
Can I paint over motorcycle plastic repair?
Yes. Sand smooth (180 then 220 grit), primer with plastic-specific primer, then paint like factory.
What plastic type are motorcycle fairings?
Usually PP (polypropylene) or ABS. Look for triangle-code molded into plastic.
How long does motorcycle body repair take?
DIY plastic weld + paint: 2-4 hours. Shop fairing repair: 3-5 days. Complete crash rebuild: 2-6 weeks.
Bottom line
Get quotes via our free quote form, or browse verified shops in our directory.