Sometimes, if an operator tries to close the zipper by only pulling on the slider, too much stress is put on the zipper elements and the zipper may pop open during the seat assembly process. The good news is that both YKK’s 5CH CONCEAL® zipper and 5CI conventional zipper for rear seats can be repaired on the assembly line without removing the whole trim cover. To repair the zipper, customers should utilize the 5CH repair kit provided by YKK and follow the step-by-step instructions outlined here. In doing so, customers can avoid scrapping material and drastically reduce the tear down process. YKK also offers on-site support to ensure operators and supervisors have a full understanding of how to do repairs. Please contact us if you would like to learn more about this service.

1. 1
5CH CONCEAL®
Zipper Repair
Procedure

2. 2
Improper Installation Scenarios
YKK® 5CH CONCEAL® Zipper Repair Procedure
Slider Comes Off and Zipper Opens
Slider Comes Off
Zipper Pops Open

3. 3
5CH CONCEAL® Repair Kit Contents
Repair Tool Notched Cutter
Crimp Tool Pliers

4. 4
Slider Comes Off and Zipper Opens
Step 1 Step 2
Align each end of the zipper
chains and cut away frayed
ends with notched cutter.
Loosen zipper Repair Tool
slightly so zipper chain slides
easily into tool. Load each side
of zipper chain into the tool.
Be sure to rotate zipper chain
in correct closing orientation.

5. 5
Slider Comes Off and Zipper Opens
Step 3 Step 4
Align the zipper chains within
the Repair Tool and tighten.
Assure the ends of the zipper
chains are aligned and pull
each side of the zipper chain
through the tool using the
pliers.

6. 6
Slider Comes Off and Zipper Opens
Step 5 Step 6
Pull the Repair Tool to close
out the zipper opening.
Orient the center of the zipper
with the blade in the notch of
the Notched Cutter and push
zipper in till it hits the back stop.
Cut to separate zipper chains.

7. 7
Slider Comes Off and Zipper Opens
Step 7 Step 8
Load slider onto zipper chain
until the slider touches the
Repair Tool.
Loosen Repair Tool and
remove from zipper chain. Pull
top towards you after loosening.
There will still be a small gap in
the zipper chain.

8. 8
Slider Comes Off and Zipper Opens
Step 9 Step 10
Gently pull the slider up and
down until zipper gap is
completely closed. Then pull
slider down slowly closing the
zipper.
Put the zipper stops on the
crimp tool as shown in picture.

9. 9
Slider Comes Off and Zipper Opens
Step 11 Step 12
Align the zipper stop on the
zipper teeth and clamp it
10mm from the end of the
zipper. (Repeat on other side)
Pull slider down till it hits the
zipper end stops, and tuck
zipper tail in the seat.

10. 10
Slider Comes Off OR Zipper Pops Open
Slider Comes Off
Follow Steps 6, 7*, and 10 - 12.
Zipper Pops Open
Remove slider from seat.
Complete steps 1 through 12.
*Repair Tool not needed
YKK and CONCEAL are registered trademarks of YKK CORPORATION
©2022 YKK (U.S.A.) Inc..