DIY Tutorial - Tire Fender Replacement

With the leg shield removed, it's much easier to get access to everything and remove the tire fender. Now onto the tire fender removal tutorial:

Step 1:

There are two screws on each side of the tire fender. Remove all 4. The lower right side (left if you're facing the scooter) one is shown here.

This is the new fender. Note that the two holes on each of the far sides is open. The suspension components fit in this space. As you can see, the fender can easily slip though the unfinished circle. There are two other holes in the center however. The tiny one is a screw which needs to be unscrewed from underneath in one of the next steps. The other larger ovular hole is where the speedometer cable needs to be pulled out from.


Step 2:
There are two hex screws shown in this photo. Remove those. They both secure the front half of the tire fender to the rear. We're only removing the front half, so these need to be take out. It's a bit tough to get access to it being that everything is so tight. But here's a tip...







....reach underneath the right side of the scooter where there's a larger notch in the rear portion of the tire fender where it's easier to access and see what you're doing. Using the circular side of the 10mm screwdriver, remove these two bolts. This is the toughest part. It'll take time and patience, it's worth it once it's done.







Step 3:
Here's the scary part - not really. I looked it up in the service manual that I downloaded and what appears to be a hose is actually the speedometer cable. It's not a brake line. Worse thing that can happen is that this thing no longer functions which means the speedometer won't work. Worse thing that can happen with a brake line? Lots worse.


So the rubber hose is unscrewed (I used a pair of pliers), pull it gently to reveal the cable inside. Pull further until it looks like the photo here. It's really dirty. I didn't bother cleaning it b/c I don't know enough about what that black stuff is? Dirt? Lube? If I clean it, do I need to relube? Errr, I have no idea.




Step 4:
This is the easy step. Just pull the cable/hose up through the hole. Since the leg shield has been removed, there's plenty of access. This photo shows the gap between the black dust shield and the tire fender. See the hose peeping through?








Step 5:
By now, 6 screws have been removed - four on the sides of the fender and 2 underneath. Everything is now ready to remove. Tug at the tire fender gently. You'll notice that it fits fairly tight. See in the photo how the width of the suspension components (black spring-like thingy) is wider than the width of the fender? You'll have to gently stretch the fender outwards to clear these shocks.


The scooter should now look like this! Bare naked! If you feel like changing the horn to something louder, now's a good time. I still haven't had a chance to buy the stripped screw remover (stripped it last time when I tried to do it), so I can't replace it now. Maybe later. Stock horn works okay for now.












This is the underside of the fender that was just removed. These next few steps are to remove the components from the old damaged tire fender and place them onto the new fender.






Step 6:
Remove these screw tabs from the old fender and secure them to the new one before you lose them. There's one in each corner.






Step 7:
One of the pieces is this rubber gasket. It pulls out like the bottom cover of a piggy bank. Secure the ring to the new fender.






Step 8:
One of the safety components are the orange reflectors. Remove these with the same 10mm wrench you've been using, Locktite the screws and secure them to the new fender. Locktite probably isn't required, but I noticed they used it at the factory so I figured I'd do the same.



Step 9:
Remove the structural piece from the old fender and place it on the new. This will require removing the screw on either side and the bolt clip shown here.






Step 10:
When you secure the black metal piece to the new fender, be sure that the tiny hole in the bracket here aligns with the hole in the fender. This will make reinstalling it on the scooter much easier. You'll have to do it anyway so may as well do it now.




Step 11:
Reverse all the steps and tada! The new front fender is on!