boxcar
Novice Class
Posts: 35
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posted March 20, 2009 02:44 PM
How hard to replace front fender?
I haven't really had a chance to look yet as my bike is still in winter storage, possibly 60 cm's of snow here overnight so probly won't be coming out soon, but the dealer just delivered my new front fender (they scratched the original when i bought it). How much work is there to changing them out? Do I need to remove the wheel in order to do it and is it worth the hassle seeing as the original only has a small mark on it? Thx for the help.
  
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Rook
Pro
Posts: 1125
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posted March 20, 2009 03:45 PM
The front fender is easy to take off. The brake line retainers (small plastic hoops) are the worst PITAs I've come across yet.
Putting the fender back on was a little tricky to get it in place but I am sure anyone could do that with a little patients. The brake line retainers snap back in place very easy.......getting them out without breaking them is the hard part.
Give me a few minutes to look at my bike and I'll be right back to give you a couple tips.
Rook
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Rook
Pro
Posts: 1125
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posted March 20, 2009 04:47 PM
 Edited By: Rook on 21 Mar 2009 00:52
OK --
You will need a 5mm hex key, an 8mm socket or wrench (careful you don't scratch anything if you use a wrench), a pencil or other writing tool, maybe some silicone spray (if have to buy some, don't worry, you'll use it all the time on your plastic and rubber parts).
The front fender removal/install is sec 15-18, "Frame" in the service manual(If you don't have one, you can download one here on this forum).
You need to remove the 2 plastic hose clamps from the back top of the fender. They are hard to get out. They will not simply pull out. The point inside the fender must be squeazed together so that it reduces in diameter enough to pull through the hole. Ever see the underside of an octopus? Well.....they have a beak for a mouth. that is exactly what the projections that retain your hose clamps look like. You have to squeaze that beak closed a bit and they will pull out but believe me, it takes work and care to avoid breaking them. Hope your hands aren't too big. I just about busted my fingers. You are going to feel some pain here so be prepared. LOL
The third plastic hose clamp on the side of the fender is 3x as bad as the top two. I don't think I was able to remove it without taking the whole fender loose. You just can't reach up in that space no matter how small your hands are.
**It will probabley be a lot easier if you just get all 4 fasteners out of the fender and then reach up in there to get the hose clamps out.
To remove the fender, just take out the silver cap screw on each side wing of the fender. You will use a 5mm hex key socket or 5 mm allen wrench. Be careful that you do not loose the black plastic washer on theses screws. Next take out the bolt at the top of the brake bracket on both sides using an 8 mm socket. This bolt is painted black and holds down the front reflector bracket as well. Be sure you mark the inside of the reflector bracket "R" and "L" with a pencil or or a Sharpie so you can easily put it back on the correct side (or just take this opportunity to leave the reflectors off for ever). Your fender will slide right out.
Installation is reverse. The hose clamps just push right in neatly. I put a drop of silicone on each one before popping it back in. You might want to try some silicone spray applied with a Q-tip to penetrate down into the projection of the hose clamp before you remove it. It should pull out easier but I would imagine it will be a little harder to squeaze that beak closed if it's all slippery.
Good luck. Post back if you have more questions. We will help you out.
Rook
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