XR650L Acerbis Fender Modification
I decided to purchase new tires for my 2002 Honda XR650L. Since I primarily use my scoot on the street I went with a set of Avon Distanzias. While at the motorcycle store (a.k.a. candy store) I spied an Acerbis Supermoto front fender that caught my attention. I read the package information and found that this fender wasn't listed as fitting my XR650L. The person who worked at the store said that the fender was generic and gave me some sort of assurance that it would fit requiring only the need to drill holes. I can drill holes along with the best of them so I purchased the fender.
There was indeed a slight complication. The wiring harness along with its corregated housing will prevent the installation of the fender. The new Acerbis fender had a recess similar to the original Honda fender however it wasn't sufficient enough to accomodate the wiring harness. Should I re-route the harness? Should I squash the harness between the fender and lower triple tree assembly? Should I cut the harness and just get rid of it? Maybe I should return the fender. Nope, I was going to get this sucker to fit one way or another. The following was my appooach. If you find yourself in this situation this maybe info may help.
I looked into my junk drawers and saw some automotive shock absorber bushings and got an idea, I would space the fender out using the bushings. I was concerned that simply using the bushings by themselves may cause the mounting bolts to loosen over time so I would put a metal insert within the bushings to I can achieve a positive tightening surface.
The rest is easy. You'll need four new 6mm bolts approximately 1 1/2 in. long. I don't know what the actual metric length is. Now you're ready to bolt it up. When you finished it will look something like this.