Front Fender

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Removal

Remove the seat. See the Seat topic for more information.

Remove the side covers. See the Side Covers topic for more information.

Remove the front carrier. See the Bumpers and Carriers topic for more information.

Remove the two (one per side) headlight mountings screws from each side of the front bumper.

Unplug the two 3-pin headlight connectors.

Remove the two trim clips on the 2005 and newer 650 models.

Remove the two trim clips on each side from inside the front fender.

Remove the two trim clips and pull back the rubber cover.

Remove the two middle cover mounting screws and washers with a #3 Phillips screwdriver.

On the 2002 – 2003 and 700 models remove the two front fender mounting screws on the left side and the single screw on the right side.

On each side there are three screws and nuts that hold the front fender flaps to the footrests. Remove the screws and nuts with a #3 Phillips screwdriver and a 10 mm socket.

Remove the ignition switch nut with a 27 mm wrench.

Lift up the front fender.

Unplug the power outlet bullet connectors.

Remove the front fender.

To remove the headlights see the Lights topic for more information.

Installation

Move the front fender into place.

Plug in the power outlet bullet connectors.

Plug in the two 3-pin headlight connectors.

Fit the front fender into place.

Install the ignition switch into the front fender. Thread on the nut and tighten it securely with a 27 mm socket.

On the 2002 – 2003 and 700 models install the two front fender mounting screws on the left side and the single screw on the right side.

Install the three (each side) screws and nuts that hold the front fender flaps to the footrests.

Hold the screws with a #3 Phillips screwdriver and tighten the nuts securely with a 10 mm socket.

Install the side covers. See the Side Covers topic for more information.

Install the two trim clips inside the front fender on each side.

Install the two trim clips on the 2005 and newer 650 models.

Install the two (one per side) headlight mountings screws through each side of the front bumper.

Install the front carrier. See the Bumpers and Carriers topic for more information.

Install the seat. See the Seat topic for more information.