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Front Fender Removal/Installation

 
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Front Fender Removal/Installation
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The Offscootinovs



Joined: 08 Apr 2007
Posts: 77
Location: Columbia County, NY

Post Front Fender Removal/Installation Reply with quote
Hi, All. Can any one give me an idea of what's involved to remove the front fender? The wife and I are 2-toning our scoots and would like to add the fender to the list to be painted. any info would be appreciated. Thanks.
Thu May 29, 2008 11:25 am View user's profile Send private message
matty_x



Joined: 06 Apr 2007
Posts: 1065

Post Reply with quote
You've got to remove the headset completely and drop the fork. A moderately difficult job unless you have a helper.

You'll need to lay the scooter on its side to get the fork out. Draining the gas tank is recommended. Be sure to lay the scooter on a blanket or you'll mess up your paint.

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Thu May 29, 2008 5:20 pm View user's profile Send private message
Angry J



Joined: 25 Mar 2007
Posts: 496
Location: Kansas City

Post Reply with quote
Conversely, if you have access to a lift or a ghetto lift like mine (2 pallets on top of 6 cinder blocks) you can leave the bike on the centerstand, and drop the fork out of the frame after removing the headset, requisite wires and cables. Must have 2 people for this way though.

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Mad Toto Scooter Club
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Thu May 29, 2008 10:45 pm View user's profile Send private message Visit poster's website
average joe



Joined: 04 Apr 2007
Posts: 257
Location: Jersey Shore

Post Reply with quote
I watched the mechanic at Scooters Originally do my new fender. He did not put it on a lift, worked completely off the center stand, pulled the whole fork out that way. If I knew you could do it that way, I would have done it myself....It took him less than an hour, and he did it all by himself, while I waited and watched.....
Fri May 30, 2008 12:45 am View user's profile Send private message
Angry J



Joined: 25 Mar 2007
Posts: 496
Location: Kansas City

Post Reply with quote
That's cool. I had no idea it could be done with the bike standing only on the center stand. I've only seen it done on a vespa, so that's where my info was coming from. Embarassed

One more reason it seems to stick by my mantra of late..."The more I work on my Vespa, the more I love my Bajaj."

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Mad Toto Scooter Club
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Fri May 30, 2008 3:32 pm View user's profile Send private message Visit poster's website
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Reply with quote
I am preparing mentally & spiritually (Ohmmmmmm) as I near the start date for the removal of my fork (column).
I'm as nervous as a cat, in a room full of rocking chairs I tell ya.
Yeah, I have removed the column from my GT200...but I didn't have to put it back together. What is really blowing
my mind though is, the whole cable thingy...you know, the shifter, brake & throttle stuff...
Like I said, I can take it apart...but I haven't attempted to adjust all the cables yet... should I be A-Feared? Shocked
Do I need any special tools for the removal of the column?
I also bought a complete set of cables & a 4th hand tool and plan to replace all... why not... I'm already in there...
-- can anyone offer any additional advice for this noob?

I am buying a motorcycle jack... it will lift to about 16" and I am going to put it on top of a dolly that is about 5" tall...
I'm doing this because I think the extra height will be a benefit, we'll see.

This has nothing to do with the column but I bought a 240ft lb electric torque wrench today (thanks for the idea Matty-X)
... I had no idea an electric wrench could have that much power... It worked great on my wheel hub... Very Happy

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Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Sat Sep 13, 2008 2:07 am View user's profile Send private message Visit poster's website Yahoo Messenger
matty_x



Joined: 06 Apr 2007
Posts: 1065

Post Reply with quote
Cowboydoug, all you need to disconnect cable wise is the front brake and speedo cable. You can leave everything else attached and just let it hang from the frame after you disconnect the headset bottom (one bolt).

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Sat Sep 13, 2008 3:39 am View user's profile Send private message
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Reply with quote
matty_x wrote:
Cowboydoug, all you need to disconnect cable wise is the front brake and speedo cable. You can leave everything else attached and just let it hang from the frame after you disconnect the headset bottom (one bolt).


No Kidding Matty?
I guess I didn't think the throttle & shifter could be lifted up & off the column while the cables were connected.
The BOLT you refer to, that is the one in the neck where the hole in the column is, just below the headset?
How is that so... can you elaborate?
Are you telling me there is one bolt to undo and the column will drop? I thought there would be some rings
that would have to be unscrewed... yes? No?

thanks

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Sat Sep 13, 2008 3:50 am View user's profile Send private message Visit poster's website Yahoo Messenger
Crusader Tom



Joined: 10 Aug 2008
Posts: 513
Location: Kansas City, Kansas

Post Reply with quote
...do as you will. ...but, i've painted at least fifty scooters(some multiple times...) and never, i'm saying; i never removed the front fender just for painting... if it's a rebuild or the fender needs to be replaced, sure, but it's not hard to mask off the other parts... a helluva' lot easier than dropping the fork! actually the dropping is the easy part... putting the SOB back in sucks. masking tape and news paper is allot easier than fucking with that fork... and if your doing a two tone paint job you'll be doing a lot of masking anyways...

my two cents.

good luck!

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Sat Sep 13, 2008 3:38 pm View user's profile Send private message
rufusswan



Joined: 29 Sep 2007
Posts: 1786
Location: Taneyville, Missouri

Post Reply with quote
I agree with Tom here. You can expose dern neer all of the front fender quite easily, and between tape and newsprint could paint a more-than-fair job a lot quicker than droppin' the fork.

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Sat Sep 13, 2008 3:44 pm View user's profile Send private message Send e-mail MSN Messenger
average joe



Joined: 04 Apr 2007
Posts: 257
Location: Jersey Shore

Post Reply with quote
Don't remove the fender unless you have to. There are a series of Bering's in the column, and the nut needs to be torqued to a specific lb. If you want to paint the fender, try to do it on the sccot, you will be thankful later on....
Sat Sep 13, 2008 11:50 pm View user's profile Send private message
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Reply with quote
I think I need to ass.. I mean add... that was a real typo so I left it...........haha
I need to add...
I am planning to paint the front of the leg shield as well...
I noticed that I could pretty much so paint the fender without removing the column.
If that were simply the case I believe I could just undo a few bolts and spin the dang
thing... but...i my case... yeah... I do believe I need to remove the column...

As for torquing... I had a lucky Saturday at the yard sales... I met a gal... and pretty good
looking too... but I digress.... her husband, the fool and ass left her and their kids for another
woman... So... she was selling off all of his tools... and believe me... she was loving it and believe
me... he has nice tools... (ummm... that sounds sick, so I mean it in the literal form) ...
craftsman and SnapOn ...i will take them all day... so I bought 2 torque wrenches... low & high...
so I am not so worried about torquing to the correct setting...
I am simply looking for advice...comfort........hahaha
I realize there are many bearings in there... heaven help me...
If you have done it.. I could use your help...
I WILL BE TAKING STEP BY STEP PIX AS GO THRU THE PROCESS... AND I WILL POST FOR FUTURE
NEEDIES...
I may even appreciate 911 numbers to call... it pains me to be without my scoot for more than 12 hours
and I have adjusted my sleeping schedule as a result of this
Laughing

On the other side.. I had to replace my hub studs yesterday... some how I got the nut and studs sizes
crossed and totally F'd up my total thingy... I tried to by new ones from POC... yadda yadda...
and ended up going to ACE Hardware... (thank goodness for ACE... they have everything)...
I also came up with a way to plug the mirror standard holes... and will post that ASAP...looks real nice and is
smooth....

anyway... thanks gang for you input...
So... now that you know I NEED to remove the column... what's the word?
Yo

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Sun Sep 14, 2008 5:45 am View user's profile Send private message Visit poster's website Yahoo Messenger
Crusader Tom



Joined: 10 Aug 2008
Posts: 513
Location: Kansas City, Kansas

Post Reply with quote
...i've unfortunately, have had to remove several fork/columns from Vespas. i've not (nor do i ever look forward to) removed a chetak fork. on the vespas you need a special "column wrench". if you don't have this then you can do it the hard way...you can use a sturdy flat screwdriver or punch and knock the top column nut loose. then use a big pair of channel-lock pliers to remove the nut. (on the vespa) there is another nut that shouldn't need to be "knocked out" , just removed... now none of this sounds very hard, but there are four cables and a series of wires in the way... very much in the way... you'll have to have the bike on a lift or at least elevated on the stand(i know that someone said it doesn't have to be... but i cant see how?) after the removal of the two nuts and one bearing the fork should "drop" out. remember to disconnect your speedo and front brake... in the older Vespas the bottom bearings are "loose" and fall out all over the place and the later models are "caged" so you don't have that problem... on the chetak? the shaft should be greased so it will be messy... but thats about it. it's not hard... it's just a pain in the ass. way to big of a pain just for painting... putting it back is harder... you do really need two people to make sure the fork is seated properly. and with out the special wrench getting the two nuts tight enough is almost impossible... but with that that said... it might be different than a Vespa and i just wasted your time by telling you all this...

you obviously have skills and so far your scooter looks freaken' great. i don't think your going to have a problem doing this... you'll figure it out as your going... like i said it's just a bitch of a job... and i only drop a fork when i have to!

good luck.

-tom

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Sun Sep 14, 2008 4:17 pm View user's profile Send private message
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Reply with quote
Tom...
I am think I am going to THROW UP... Shocked
my stomach just did flip flops after I read your last post.

To all of you guys... thanks for your help on this...


I thought I had written about my motorcycle lift in here already.
I guess i didn't... so anyway...
The lift I am picking up this week lifts to 14-16"...I don't recall... to
get it higher I am mounting it on a furniture dolly... that gives me another 5-6"s.
If that isn't high enough for the column to slide out I will tilt the scooter back on the lift...
like it's popping a wheelie ... and if that doesn't work I have a friend who I
won't tell how messy and greasy the column is until he actually has it in hand...
then I will throw out an, Oh Yeah... that thing might be a bit greasy Laughing
What are friends for Laughing

and if all else fails I do have a Stella Dealer here in town, an absolute last resort.

On the upside... it sounds like it will be a good time to replace all my cables......hahahaaa

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Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Sun Sep 14, 2008 11:20 pm View user's profile Send private message Visit poster's website Yahoo Messenger
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Reply with quote
After re-reading all of your posts a few times I am taking a look at spraying the fender
and the leg shield and not removing the column.

I was just out looking at the area behind the front fender to see what kind of room
there is... I am becoming somewhat optimistic about being able to paint the leg shield
with the fender on. Has anyone tried and succeeded in doing that?

It looks like there is only a small area...just above & behind the fender and just below the
big hole that is in the front of the leg shield. It looks like an area smaller than a softball.
I might even be able to spray that area but I am guessing if I do it would be borderline
quality wise in that spot.

Opinions?

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Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Sun Sep 14, 2008 11:38 pm View user's profile Send private message Visit poster's website Yahoo Messenger
mostly_lurking



Joined: 29 Aug 2007
Posts: 94
Location: Illinois

Post Reply with quote
Quote:
only a small area...just above & behind the fender... Opinions?


I'm thinking, how often do you look at that area...
I'm thinking, it could be neon green and no one would ever notice. My opinion is that the finish quality for that particular spot just needs to do the job of rust protection. You couldn't wax that spot if you wanted to![/quote]
Mon Sep 15, 2008 2:06 am View user's profile Send private message
Crusader Tom



Joined: 10 Aug 2008
Posts: 513
Location: Kansas City, Kansas

Post Reply with quote
i've painted my Bajaj twice(without removal of the forks) and never had a problem...

it was stock black when i bought it.
the first paint scheme:


and two years later i changed it to this:




just take your time... it's easy work.

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Mon Sep 15, 2008 3:23 am View user's profile Send private message
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Reply with quote
Crusader Tom wrote:
i've painted my Bajaj twice(without removal of the forks) and never had a problem...

it was stock black when i bought it.
the first paint scheme:


and two years later i changed it to this:




just take your time... it's easy work.


What the HELL color is it now.... hahaha kidding...

I am thinking I can removed the front wheel & hub & undo the fender bolts and swivel it....right?
That should do the trick...
Say it... yes doug...you are catching on........................lol Laughing

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Mon Sep 15, 2008 5:10 am View user's profile Send private message Visit poster's website Yahoo Messenger
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Reply with quote
I don't care what your parents say... you guys are all alright........hehehe Laughing

so...am I right... I can remove the front wheel... and undo the fender bolts and swivels it?

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Mon Sep 15, 2008 5:12 am View user's profile Send private message Visit poster's website Yahoo Messenger
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Reply with quote
and while we are on it...
I love the Chetak horncast... BUT hate the turn signal thingies...
it just doesn't work for me... so I am cutting it off and will use fiberglass &
resins to fill the voids...
you'll see... well I hope.............providing i don't screw the pooch..........lol

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Mon Sep 15, 2008 5:19 am View user's profile Send private message Visit poster's website Yahoo Messenger
Crusader Tom



Joined: 10 Aug 2008
Posts: 513
Location: Kansas City, Kansas

Post Reply with quote
cowboydoug wrote:
and while we are on it...
I love the Chetak horncast... BUT hate the turn signal thingies...
it just doesn't work for me... so I am cutting it off and will use fiberglass &
resins to fill the voids...
you'll see... well I hope.............providing i don't screw the pooch..........lol


there is this stuff called "tiger hair" it's a resin product. it works great! super durable and holds paint... check it out.

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Mon Sep 15, 2008 1:09 pm View user's profile Send private message
Crusader Tom



Joined: 10 Aug 2008
Posts: 513
Location: Kansas City, Kansas

Post Reply with quote
cowboydoug wrote:
I don't care what your parents say... you guys are all alright........hehehe Laughing

so...am I right... I can remove the front wheel... and undo the fender bolts and swivels it?


...yep. but the problem with that is the tendency for it to "jiggle" and hit the leg shield... with out the bolts it's very squirrelly...
but take your time and it can be done

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i'm uncool. and i'm cool with that.
Mon Sep 15, 2008 1:22 pm View user's profile Send private message
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Reply with quote
Crusader Tom wrote:
cowboydoug wrote:

so...am I right... I can remove the front wheel... and undo the fender bolts and swivels it?


...yep. but the problem with that is the tendency for it to "jiggle" and hit the leg shield... with out the bolts it's very squirrelly...
but take your time and it can be done


Okie dokie... then I'm set...
I'm just going to remove the wheel & hub (I'm painting the hubs too)
un-bolt the fender so I can move it around enough to "Get'R Done" Laughing

Much better than dropping the column... that's for sure.

muchos Grassyass

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Mon Sep 15, 2008 5:19 pm View user's profile Send private message Visit poster's website Yahoo Messenger
matty_x



Joined: 06 Apr 2007
Posts: 1065

Post Reply with quote
Quote:
No Kidding Matty?
I guess I didn't think the throttle & shifter could be lifted up & off the column while the cables were connected.
The BOLT you refer to, that is the one in the neck where the hole in the column is, just below the headset?
How is that so... can you elaborate?
Are you telling me there is one bolt to undo and the column will drop? I thought there would be some rings
that would have to be unscrewed... yes? No?


Actually, I see that something went wonky when I posted. I included another three paragraphs on how to drop the fork... but it looks like I should not post using an iPhone anymore because that obviously doesn't work.

Long story short is, yes, you can do it with only removing the cables for the front end, but it's even more of a PITA than doing it the "right" way - which is disengaging all cables.

If I'm painting the front fender, I drop the forks. But that's just how I do it. I retouched my front fender recently after my spill without dropping the forks... but that was just a touch up. If you're doing it yourself, I think you'll be well served by just leaving it on and taping everything else up.

A tip - overspray on your front tire looks mad ghetto.

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Mon Sep 15, 2008 7:15 pm View user's profile Send private message
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Reply with quote
matty_x wrote:
Quote:
No Kidding Matty?
I guess I didn't think the throttle & shifter could be lifted up & off the column while the cables were connected.
The BOLT you refer to, that is the one in the neck where the hole in the column is, just below the headset?
How is that so... can you elaborate?
Are you telling me there is one bolt to undo and the column will drop? I thought there would be some rings
that would have to be unscrewed... yes? No?



A tip - overspray on your front tire looks mad ghetto.


We can't have no stinking ghetto man... Laughing

thanks for your tips Matty... I would love to have read the 3 lost paragraphs....

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Mon Sep 15, 2008 9:01 pm View user's profile Send private message Visit poster's website Yahoo Messenger
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