The rear fender assembly includes the license plate bracket with side reflectors, tail light housing, turn signals and stalk, the cowling tool box and the rear wiring sub-harness.
Remove License Plate Bracket and Mud Flap
The license plate bracket includes side reflectors and is secured to the fender with three bolts with lock nuts that are underneath the license plate. This bike has the rubber rear mud flap that is secured to the sides of the fender with three bolts and lock nuts. I remove these.
I remove the lock nut from the side reflectors as I am going to powder coat the license plate bracket.
The mud flap attaches to the sides of the fenders.
And, the bike still has a tire pump. 🙂
Remove Tail Light Housing
The tail light lens is secured with two Phillips screws.
Inside, is the reflector with a separate bulb for the parking light (lower) and the stop light (upper). The tail light bulb is a “797” and stop light bulb is a “1156” single filament bulb.
The back of the reflector housing includes terminals for the parking light wire BLACK-White, the stop light wire, GREEN-Red and the ground wires, BROWN.
The wires that go to the parking light and stop light come in the bottom of the black tail light housing through a rubber grommet.
The tail light housing is secured to the fender with two bolts and a metal strap inside the fender with nuts and a wave washer inside the housing. Someone added some rubber grommets that went between the fender and the housing.
I remove the tail light housing exposing the a cable with wires going into the housing and the another cable of wires that go to the turn signals through the turn signal stalk.
The rear wiring sub-harness is secured to the top side of the fender with three plastic cable holder loops that fit into holes in the fender.
Remove Turn Signals
I remove the two screws that secure the turn signal lens to the housing.
Each turn signal reflector has a single filament bulb and two wires; a BLUE-Black (right side), or BLUE-Red (left side), and a BROWN wire.
The turn signal housing is secured to the stalk with a bracket that has two screws. I remove this to remove the turn signal housing from the stalk.
Then I carefully pull the four wires out of the stalk through the hole in the middle of the stalk.
Then I remove the rear sub-harness that is still connected to the tail light assembly by disconnecting the plug near the left sub-frame mounting bolt. I thread the sub-harness plug through the cable holders as they are easier to remove from the inside of the fender when I get it off.
The front of the rear fender is attached to the sub-frame at the sub-frame cross-brace the rear of fender is attached through the cowling tool box.
The sticker next to the sub-frame cross brace shows the paint code, 542, which is Alaska Blue (Metallic).
Remove Rear Fender Bracket
The rear fender bracket is attached inside the cowling tool box with two lock nuts with wave washers and a metal strap. A second metal strap with a nut, wave washer and large flat washer is inside the fender
There is a rubber grommet and flat washer between the top of the fender and the tabs on the sub-frame.
In the picture above, someone put two of the flat washers on one of the bolts when there should only be one.
In the picture above, the flat washer under the bolt head is smaller (about 10 mm diameter) than the one on top of the rubber grommet (about 14 mm).
There is a sticker on the back of the cowling tool box, a casting number on the inside (not the part number) and two rubber grommets on the bottom.
Remove Front Fender Bracket
The front fender bracket attaches to the rear sub-frame cross brace with two locking nuts with flat washers. There is the same rubber grommet between the top of the fender and the bottom of the cross brace. Inside the fender is the same metal strap, the head of the bolts and a wave washer.
Here is the fender with the stickers.
Remove Rear Sub-harness Hangers
There are three plastic hangers that hold the rear wiring sub-harness on the rear fender.
I remove these using a drift to push them out of the fender from the inside. I don’t use a hammer as I’m careful with these as they are no longer available.
You could also try removing them from the front using a small blade screw driver if you are careful.
Here is bike with the rear fender assembly removed.