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Plastic tooth (Vislon®) zippers are comprised of a multitude of small parts that come together to allow the zipper to function. When one or more plastic teeth are missing from the zipper tape, the zipper may not function properly, causing the zipper to split or the zipper slider to come off the track.
This guide provides step-by-step instructions for installing YKK Revived Replacement Parts, utilizing a specialized tool developed by YKK for replacing individual teeth on #5VS zippers.
This guide is intended for professional repair technicians with access to these tools.
Alternatively, Patagonia products can be taken to a local retail store for repair evaluation or sent in to Patagonia through their mail-in repair service.
IMPORTANT! Before proceeding:
1. Identify the type of zipper to ensure the product is eligible for this repair.
2. Ensure the damage is only to the teeth of the zipper by referring to plastic tooth zipper issue diagnosis.
WARNING! Small Parts. Patagonia does not recommend conducting these repairs on garments intended for children age 3 or under. Instead, we recommend return of the product for professional repair services.
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YKK Revived Replacement Pliers
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YKK Revived Replacement Set Plate
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YKK Revived Replacement Teeth
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Reference the Zipper Identification guide to confirm the appropriate zipper type and size. The set plate and replacement teeth are currently only compatible with #5VS zippers which are non-coated, size 5, with plastic teeth.
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Unzip the zipper.
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Double check that there are no other issues with the zipper line, like a missing box, a damaged pin, or torn tape.
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Locate the area(s) on the zipper tape where teeth are missing.
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Check the teeth adjacent to the voided area.
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If a tooth is damaged, use end cutting nippers to remove the damaged tooth from the tape by snipping along the edge of the tooth, then peeling the rest of the tooth away from the tape.
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Check the existing zipper slider:
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If the slider is still in place, move to the next step.
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If the slider is missing, and there are missing teeth on the box side of the zipper line, use any voided area on the zipper line to place a new slider onto the track. Then move on to the next step.
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If the slider is missing, and no teeth are missing or damaged on the box side of the zipper line, follow the Plastic Tooth Zipper Slider Replacement guide. Then move on to the next step.
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Align a single replacement tooth onto the zipper tape beside an existing undamaged plastic tooth.
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Open the set plate and slide it under the zipper teeth so the replacement tooth sits in the marked groove at the edge of the set plate.
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Close the set plate and position the pliers into the horizontal indent in the center of the set plate.
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Crimp the replacement tooth by squeezing the pliers firmly.
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Repeat the previous two steps for any additional missing teeth.
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Plan the order of replacements so each tooth being replaced is always adjacent on the zipper tape to an existing undamaged tooth or newly replaced tooth.
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To install teeth close to other zipper parts such as the box or pin, follow the previous steps while carefully placing the set plate away from the part.
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Zip up the previously damaged zipper line.
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Pull horizontally on either side of the garment to check if the zipper splits.
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With the zipper closed, check that the newly installed teeth properly align with the teeth on the other side of the zipper.
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Make a final check to ensure that the zipper slider moves smoothly over the replacement teeth:
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Tooth is Loose: Tooth isn't firmly adhered to zipper tape and wiggles when touched.
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Not Enough Pressure: Tooth sits firmly and doesn't wiggle, but the tooth is too thick so the slider doesn't glide smoothly over replacement teeth.
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In both cases, reapply the rig and apply firm pressure until the tooth doesn't wiggle and the slider moves smoothly over it.
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If available, use a set of calipers to ensure that the height of the replacement tooth is the same as the existing teeth.
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Variations: There are many varieties of plastic tooth zippers, including different sizes and shapes of sliders and teeth. Currently, YKK only provides replacement teeth and tools for #5VS zippers.
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Missing Zipper Sliders: If the zipper slider is missing, replace the slider prior to replacing any teeth. Test the slider to ensure that it's the appropriate size and style for the item.
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Pocket: Pocket zipper teeth can also be replaced with this process as long as the teeth of the zipper are #5VS. However, replacing teeth next to bottom and top stops may not be possible due to the set plate's shape.
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