ADVrider

Go Back   ADVrider > Bikes > Road warriors
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 01-04-2012, 05:26 PM   #826
ORexpat
Oregon Expatriate
 
ORexpat's Avatar
 
Joined: Jan 2007
Location: West of Seattle . . .
Oddometer: 2,631
Fender re-hab

We all know how poor the chrome work is on the Dubya fenders; mine showed some significant rusting. Here's a pic of the rear fender after it was off. The front fender had a lot more rust.



Not so bad back by the tail light.



Taking the fender off is really easy with the rear wheel removed--and the front is even easier--4 bolts and the front's ready to work on.

On page 48 of this thread The Jerk has a really nice pictorial of removing the rear fender without removing the wheel. Nice photos, nice work.

Starting to take the rust down.



You can see the difference here.



JB Weld "Kwik" epoxy and some metal rod. This should keep the rear fender from cracking . . .



What I hope is the "holy trinity." Several coats of Hammerite first, then primer, then silver Rustoleum.



Partially painted.



Painted. I didn't bother to sand the JB Weld--its underneath and I wanted as much material there as possible.



Started to put the rear fender back on the bike. You can see the two bolts at the front/bottom of the rear fender.



There are four bolts that hold the fender to the frame underneath the seat.



Wiring loom going back through the fender.



Wiring clipped underneath the fender. You can see the extra epoxy in this photo. Also where the masking tape covered a bit of the metal . . .



Tool tray (and stretched to uselessness) bungee back in place.



Easy project, and I think well worth doing. Between the rust and the potential fender cracks, the time spent was worth it. Only cost was the paint and the JB Weld.
__________________
Old . . . and . . . Slow

ORexpat is offline   Reply With Quote
Old 01-04-2012, 07:50 PM   #827
Barnone
Beastly Adventurer
 
Barnone's Avatar
 
Joined: Mar 2007
Location: WNC SWFL
Oddometer: 3,652
ORexpat,
Another nice job with the photos and write up. Luckily my W is still rust free under the fenders.
__________________
Vince @ SWFL or WNC
2001 Kawasaki W650
2012 Ural Yamal
2012 Dong Fang DF250RTB
Barnone is offline   Reply With Quote
Old 01-05-2012, 07:22 AM   #828
igozumn
Gnarly Adventurer
 
igozumn's Avatar
 
Joined: Dec 2011
Location: Olathe, KS
Oddometer: 112
Quote:
Originally Posted by ORexpat
Looks nice--saw the photo in the Yahoo Group.
As did I. Looks good.
__________________
'90 Voyager
'01 W650
igozumn is offline   Reply With Quote
Old 01-05-2012, 11:29 AM   #829
acap650
acap650
 
acap650's Avatar
 
Joined: Apr 2006
Location: Western PA
Oddometer: 530
Fender work

Well done ORexpat . Been there done that with the JB and rod bracing - 21K miles and no sign of a crack. No rust either but I do keep it clean and use nothing but Turtle Wash&Wax. Mixed up good and strong - waxes everything it touches.

Ride it and keep it shiney 'cause these W's are keepers.

acap650 is offline   Reply With Quote
Old 01-11-2012, 10:30 AM   #830
Barnone
Beastly Adventurer
 
Barnone's Avatar
 
Joined: Mar 2007
Location: WNC SWFL
Oddometer: 3,652
Went for a 120 mile ride yesterday on back roads at speeds up to 70 MPH and got 63 MPG. My odometer should be accurate since I now have the 16 tooth front sprocket on the W.
Did remove the small windshield and the ride is quieter without it. I wear a HJC full face helmet.
__________________
Vince @ SWFL or WNC
2001 Kawasaki W650
2012 Ural Yamal
2012 Dong Fang DF250RTB
Barnone is offline   Reply With Quote
Old 01-11-2012, 10:33 AM   #831
Barnone
Beastly Adventurer
 
Barnone's Avatar
 
Joined: Mar 2007
Location: WNC SWFL
Oddometer: 3,652
acap650,
What cap do you have on the Air Injection System manifold on your W?
__________________
Vince @ SWFL or WNC
2001 Kawasaki W650
2012 Ural Yamal
2012 Dong Fang DF250RTB
Barnone is offline   Reply With Quote
Old 01-11-2012, 03:17 PM   #832
acap650
acap650
 
acap650's Avatar
 
Joined: Apr 2006
Location: Western PA
Oddometer: 530
Quote:
Originally Posted by Barnone View Post
acap650,
What cap do you have on the Air Injection System manifold on your W?
I'm always amazed at the details that get noticed. I believe it is one of those rubber caps that are used for furniture legs - looks to be about 5/8 in. I.D.. I shortened it to around 1/2 in.. Been on there for 7 years and 18K miles - the heat doesn't seem to bother it.
acap650 is offline   Reply With Quote
Old 01-11-2012, 03:22 PM   #833
acap650
acap650
 
acap650's Avatar
 
Joined: Apr 2006
Location: Western PA
Oddometer: 530
Quote:
Originally Posted by acap650 View Post
I'm always amazed at the details that get noticed. I believe it is one of those rubber caps that are used for furniture legs - looks to be about 5/8 in. I.D.. I shortened it to around 1/2 in.. Been on there for 7 years and 18K miles - the heat doesn't seem to bother it.
Forgot to mention that I also have the steel blocking plates behind the air manifolds - I believe they were called coasters and were made by someone from the Yahoo group.
acap650 is offline   Reply With Quote
Old 01-11-2012, 03:51 PM   #834
Barnone
Beastly Adventurer
 
Barnone's Avatar
 
Joined: Mar 2007
Location: WNC SWFL
Oddometer: 3,652
Quote:
Originally Posted by acap650 View Post
Forgot to mention that I also have the steel blocking plates behind the air manifolds - I believe they were called coasters and were made by someone from the Yahoo group.
So the cap doesn't do anything?
__________________
Vince @ SWFL or WNC
2001 Kawasaki W650
2012 Ural Yamal
2012 Dong Fang DF250RTB
Barnone is offline   Reply With Quote
Old 01-12-2012, 06:58 AM   #835
acap650
acap650
 
acap650's Avatar
 
Joined: Apr 2006
Location: Western PA
Oddometer: 530
Quote:
Originally Posted by Barnone View Post
So the cap doesn't do anything?
I suppose not, so why didn't I just remove the tubes and plug the holes with something?

Some folks bought OEM manifold covers that had no air openings but there is a limit to what I'll spend on cosmetics.
acap650 is offline   Reply With Quote
Old 01-12-2012, 07:39 AM   #836
rider929
Gnarly Adventurer
 
rider929's Avatar
 
Joined: Jun 2008
Location: Central Virginia
Oddometer: 360
I had a guy at work make me a set of block-offs. They sure clean up the front of the motor.

__________________
00 W650, 82 XS 650, 74 Commando
rider929 is offline   Reply With Quote
Old 01-12-2012, 12:41 PM   #837
Barnone
Beastly Adventurer
 
Barnone's Avatar
 
Joined: Mar 2007
Location: WNC SWFL
Oddometer: 3,652
Quote:
Originally Posted by rider929 View Post
I had a guy at work make me a set of block-offs. They sure clean up the front of the motor.
That's what I did on my DF250RTB to block off the port. Just an1/8" aluminum plate.
__________________
Vince @ SWFL or WNC
2001 Kawasaki W650
2012 Ural Yamal
2012 Dong Fang DF250RTB
Barnone is offline   Reply With Quote
Old 01-12-2012, 06:56 PM   #838
rheritage
Gnarly Adventurer
 
Joined: Dec 2010
Location: Savannah, GA
Oddometer: 192
Orexpat,

Nice work on the fender, should hold up no problem. When I bought my "W" last year it was too late for the fender, bike had 25K on it and 3/8 cracks on bothe sides. Prior to laying out $225 for a new fender I'm going to "Bob" it and install a small "Lucas" style tail light and small signals moved up near the frame, I'll post some pics when done.

It's a shame Kawi had to hang such a heavy tail light/signal assembly on that fender but at least they fixed it with a new reinforced design.

Thanks,
Rich
__________________
R75/5, R75/5 AHRMA Racer, R100CS, R100GS PD, 1150GSA, WR450, Zuma 125

R100RS Sold, R80RT Sold, 1150RT Traded, RC51 Sold, KLR685 Sold, W650 Sold, CB1100F Traded, 1100S BCR Traded
rheritage is offline   Reply With Quote
Old 01-13-2012, 05:47 AM   #839
Speedo66
Transient
 
Joined: Jan 2010
Location: Cin City, OH
Oddometer: 6,144
Quote:
Originally Posted by rheritage View Post
Orexpat,

Nice work on the fender, should hold up no problem. When I bought my "W" last year it was too late for the fender, bike had 25K on it and 3/8 cracks on bothe sides. Prior to laying out $225 for a new fender I'm going to "Bob" it and install a small "Lucas" style tail light and small signals moved up near the frame, I'll post some pics when done.

It's a shame Kawi had to hang such a heavy tail light/signal assembly on that fender but at least they fixed it with a new reinforced design.

Thanks,
Rich
I did just that when I got mine, having heard of the weak fender. Remove the rear reflectors, and the holes work perfectly with smaller turn signals. I think Kaw did just that in other markets.
__________________
Oh I used to be disgusted, but now I try to be amused-E.Costello
'01 Kawasaki W650, '05 Yamaha XT225



Speedo66 is offline   Reply With Quote
Old 01-13-2012, 08:33 AM   #840
ORexpat
Oregon Expatriate
 
ORexpat's Avatar
 
Joined: Jan 2007
Location: West of Seattle . . .
Oddometer: 2,631
Because I ride in heavy DC/beltway traffic, I confess that I rather like having those big ugly turn signals way aft on the bike . . . they may be a touch more visible . . . .

At any rate, thanks for the comments about "should last a while . . . . " Sure hope so.
__________________
Old . . . and . . . Slow

ORexpat is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 04:35 PM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014