
Owners of Kawasaki KLR motorcycles sometimes choose to customise their vehicles by painting the plastic components. This process can be done using a variety of methods, including sanding, scraping, heating, and using an adhesive remover to strip the existing paint, followed by the application of primer and paint. Some owners opt for a wrap instead of paint, as it is easier and less fuss than painting, and the colour can be changed with less effort in the future.
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What You'll Learn

Sanding and scuffing
Start by removing any stickers or decals from the plastic surface. You can use a hair dryer to soften the adhesive, making it easier to peel them off. An adhesive remover can also be used for this purpose. Be careful not to damage the underlying paint job unless you plan to completely strip and repaint the entire surface. If you do need to remove paint, a product like Rapid Tac Rapid Remover can be used, but work quickly as it can melt paint and plastic if left on too long.
Once the stickers are removed, you can begin the sanding process. Start with a coarse grit sandpaper, such as 60-grit, to scuff up the surface and create a rough texture that will allow the new paint to adhere better. Always sand in the same direction, following the grain of the plastic if possible. Be thorough and ensure that you sand the entire surface evenly.
After the initial sanding, progress to a finer grit sandpaper, such as 120-grit, to smooth out the scratches left by the coarser grit. This step is important to ensure a uniform finish. Finally, you can finish sanding with an even finer grit, such as 240-grit or 400-grit, to create an even smoother surface for painting. A power sander can be useful at this stage if you have one, but it is not necessary.
Once you're satisfied with the smoothness of the surface, clean the plastics carefully with rubbing alcohol to remove any oils, dust, or residue left over from sanding. This step is crucial, as it will ensure that the new paint adheres properly and doesn't contaminate your work.
Now, your KLR plastics should be sufficiently sanded and scuffed, ready for the next steps of priming and painting. Remember, preparation is key to achieving a high-quality, long-lasting paint job.
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Removing stickers
First, clean the area with soapy water to remove any dirt and debris that could scratch the paint when removing the sticker. Next, heat the sticker with a hairdryer to loosen the adhesive. Once the sticker is heated, begin peeling it from one corner. If the sticker is particularly stubborn, you can use a product like Goo Gone or Turtle Wax Sticker Remover. Apply the product to the sticker with a rag or paper towel and let it sit for around 15 minutes to break down the adhesive. You can also try using a product like Rapid Tac Rapid Remover, but be aware that it can melt paint if left on for too long.
If there is any residue left after removing the sticker, this can be removed with distilled vinegar, nail polish remover, or a glue removal product. Soak a cotton ball, rag, or paper towel in your chosen solvent and press it onto the residue for at least 15 minutes. You can also try putting some vegetable oil on a paper towel and wiping the glue residue in a circular motion. Once the glue is gone, wash the area with soap and water.
Another option for removing stickers and residue is to use a plastic scraper, credit card, tongue depressor, or your fingernail. This method may be more suitable for removing smaller stickers or residue that is difficult to reach with a paper towel or rag.
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Using primer
Painting KLR plastics is a straightforward process, but it requires careful preparation. Once you have removed the stickers and residue, you can begin the priming process.
Firstly, it is important to prepare the surface of the plastics properly. Using a hair dryer can help to remove stickers, but for more stubborn residue, you may need to use an adhesive remover. Once the stickers and residue are removed, clean the plastics with alcohol to remove any remaining oils.
Next, you will need to rough up the surface of the plastics to help the primer adhere properly. You can do this by sanding the plastics with grit sandpaper. The recommended grit size varies depending on the source, ranging from 1000 grit to 400 grit. It is important to use a finer grit size if you are using a power sander to avoid damaging the plastics.
Once the surface is properly prepared, you can apply the primer. Several sources recommend using a plastic primer, such as Rustoleum, and applying two light coats for the best results. One source suggests using an adhesion promoter with the primer to improve the longevity of the paint job.
After the primer has dried, you can move on to the painting stage. It is important to use multiple light coats of paint instead of a few heavy coats to achieve a smooth and even finish. Make sure you follow the directions on the paint can, including the recommended weather conditions for drying.
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Painting techniques
Preparation
As with any painting job, preparation is key. Start by removing any stickers or decals from the plastic surface. This can be done by using a hair dryer to heat and loosen the stickers, followed by an adhesive remover to get rid of any remaining residue. It's important to note that if the stickers are under a clear coat, removing them will destroy the existing paint job. In this case, you may choose to sand only the parts on top of the stickers instead of removing them completely. Once the surface is free of stickers, clean it with rubbing alcohol to remove any oils or residue.
Sanding
Sanding is an important step in creating a smooth surface for painting. Use sandpaper with a grit of 400 or higher to rough up the plastic and create a texture that will allow the paint to adhere better. Start with a lower grit and gradually increase it for a smoother finish. Be careful not to over-sand, as this can damage the plastic.
Priming
After sanding, it's essential to use a plastic primer to create a base for the paint to adhere to. Apply two light coats of primer to ensure even coverage. This will help the paint stick to the plastic and result in a more durable finish.
Painting
When it comes to painting, it's recommended to use multiple light coats instead of a few heavy ones. This will help you achieve a smoother and more even finish. Choose a paint that is suitable for plastics, such as Rustoleum Painter's Touch Ultra Cover, and always follow the directions on the can. Pay attention to the weather conditions and ensure they are within the range specified on the paint can for optimal drying.
Masking
If you only want to paint certain areas, masking is crucial. Use tape and newspaper to cover the parts you don't want to paint, ensuring a clean and precise finish. Remove the masking tape immediately after applying the last coat of paint to achieve sharp lines.
Alternative Methods
Instead of painting, some people choose to wrap their KLR plastics. This involves using a heat gun and an exact knife to apply a wrap, such as 3M 2080, which can be easier and provide more options for customization. Another alternative is to use a bed liner, which is flexible and can hide imperfections.
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Drying and weather conditions
When painting KLR plastics, it is advisable to work in a well-ventilated area or outdoors, considering the paint's drying time and potential fumes. However, it is crucial to be mindful of weather conditions, especially if working outdoors. Avoid painting in extreme temperatures, whether hot or cold, as it can affect the paint's adhesion and drying time.
Optimal drying conditions typically involve a mild temperature range, moderate humidity, and good airflow. Refer to the paint manufacturer's instructions for specific guidelines on the ideal temperature and humidity levels for the paint to cure correctly. It is also essential to allow sufficient time for the paint to cure completely, which may take several hours or even days, depending on the paint type and environmental conditions.
Additionally, consider the impact of weather conditions on the painting process itself. For instance, painting in direct sunlight or during windy conditions can lead to dust or debris settling on the wet paint, compromising the final finish. Therefore, it is recommended to paint in a shaded area, protected from wind and dust, to achieve the best results.
Moreover, the drying process can be influenced by the number of paint coats applied. Applying multiple thin coats, as recommended by some KLR painters, may require more time for each layer to dry thoroughly. Consequently, the overall drying time will be extended compared to applying fewer thick coats. Thus, it is essential to factor in the number of coats and the associated drying time when planning your project.
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Frequently asked questions
You can use an adhesive remover, heat, or a hair dryer to remove stickers.
After removing the stickers, you should clean the surface with rubbing alcohol, then sand it with fine-grit sandpaper (e.g., 400-grit), and finally apply a plastic primer before painting.
You can use rattle can paint, but be aware that it is not gasoline-proof. Alternatively, you can use Rustoleum Painter's Touch Ultra Cover, applying multiple light coats instead of a few heavy ones.











































