front fender tip of the day

[ekap1200]

Well this tip is one I found out the hard way. While changing out the front tire I had noticed the plastic around one of the fender inserts had a small crack. What has happened is that in time those inserts will crush down and put allot of pressure on the plastic. In the past I had never thought of inspecting them closely and to my surprise when I laid one down into the fender there was a gap showing between the spacer and nut plate. So goes to show how such a small part can become an expensive replacement of another item. Not to mention that the fork brace is now not metal to metal , but with a plastic washer so to speak , and the risk of cracking the fender even more. Called Carl and he confirmed this little bit of fender trivia fact...
So take a good look at these little items and save a fender next time you have it off. Carl can still get these , But you guys know I just whipped them up on the lathe out of 303 stainless GENE

[debron]

Photos! We want photos!

[ekap1200]

Photos! We want photos!

OK Ron, you know I like pics




these are the inserts I am talking about. Carl has told me they should stand proud of the plastic when they are new, When you tighten down on the fork brace they will crush just enough to secure the plastic but retain a good metal to metal contact between the fork brace and the ( nut plate ) under the fender plastic. The bottom pic shows the old one's and the new ones that I made up on the lathe.

[debron]

Thanks for the tip Gene. I will check those out on my next removal of the fender.

[Lucasind]

....great tip gene, the pieces you made look great, love the use of stainless where ever possible !

[HMB Don]

Gene

I hope you bring a lot of these items to sell at the AVA Rally this summer.

[ekap1200]

Gene

I hope you bring a lot of these items to sell at the AVA Rally this summer.

Gee that's easy for a retired guy to say, If you lived here in NJ I'd put you to work.. ..I can hardly find time to service my bike. Started out with " oh I'll just change out the tires " Too lets pull the drive line, rpl fuel filter ,rpl air flt , rpl oil/filter , U-Joint rpl , front rotors rpl, {fender/fork-brace inserts, manufacture and rpl },{reverse engineer and manufacture- front vent set-polished/Brass/ instl. Oh and I am finally getting around to replace the rear pads ,and the Nor-Cal fluid/line you gave me two rally's ago / What the heck I'll use up the new bottle of brake fluid and flush/fill all chambers , and change the coolant while its got the plastic off. I will try to have some set's in inventory and for the rally , ( vent trim- in stainless and brass ) Mirror trim -in stainless , some trunk mirrors left in stock and if I get some time and piddle , some Kawasaki napkin holders, All this when I get home from the day job, at 6:00 pm .. See ya soon in the Smokey's , Don Gene Kap..

[lonewolf3253]

Good tip.....Just too late for me ....
Now to fix the problem, just getting around to installing all the chrome and stainless(from Gene) when I found the cracked fender. it is what I would call spider webbed with cracks. Got a new(used) fender from ebay and don't want to have it crack in the same way. I am installing the fender rails with the marker lights and the Kawasaki instructions says to discard the washers because they are not needed with the chrome trim. Anyone have any suggestions on this.

[lonewolf3253]

Just to pass along the info, I talked to Carl Leo and the inserts should be installed with the fender rails. They should stand .002"-.003" off the fender before tightening.