View Full Version : Maiers Install / Fender Cutting Thread

04-07-2003, 06:38 AM
Well I got the new Maiers last week and was installed them thurs. & friday night after work... It was a bigger job than expected but not to bad over all.

1. I started by cleaning my old plastics since it's easier to do when they are on the bike. I like to use paint thinner since it will take everything off. Just make sure you don't have a lit cig near it and you are in a vented area.

2. Remove all plastics.... If you can't figure out how to do this than you shouldn't be installing the new fenders your self.

3. Set the rear fender upside down. Use a blanket underneath so you don't scratch up your new stuff.

4. Install the rubber stops, etc. This is easy to do by sliding one half of the rubber in the hole and with a small flat screw driver pushing the other side through. You do not need to use anything to lubricate the rubber... This will just make it harder to grip while you are pushing through.

5. Install stock metal rod (fender support), drillling instructions and mounting comes with rear fender.

6. Install rear latch, at this time your seat should be on and your rear fender done.

7. Install light plastics onto the new front fender. You will have to drill and put mounts that will hold the stock light plastic on from the rear.

8. Install lights and switches.

9. Put front fender on quad, look where it should be mounted. Bolt the side plastics only from the lower frame mount. This way you can aline the plastics before drilling. Get tape to secure to front fender while it is alined. Once they are alined and taped unbolt the side plastics and remove the front fender once again with the side fenders now attached.

10. Now that the side fenders are now attached to the front you can bolt them up to the front at this time. Bolt are included.

11. Put all fenders support brackets ont hat come with the kit as the direction tell you to. I did not put on the front support towards the back wsince I did not add fender extensions and I planned on cutteing the fenders right away. The support twards the rear of the bike is not needed and taking them off also reduce weight.

12. Once fenders supports ( above shock) are on you can put your front fender with side still attached onto bike. Now you can alight the brakets better to bolt up the fenders. At this time I put the tank cover over it to make sure ever thing would aline. After making sure the front was centered and everything was good I put tape where I figured I would drill since the fenders were black there is no place to mark the cuts.

13. Mark drill points with pen, remove fenders, now drill.

14. put front fenders with sides back on, bolt them up, fix anything that needs to be at this point.

15. Snap 4 stock clips into tank which hold tank to side fender and tank to front fender. I had to drill the holes bigger to make the stock clips fit.

16. Put rear on and you done.

04-07-2003, 06:42 AM
Now to cutting.

1. Mark where you will cut with electricl tape. Well that si what i like to use. Make sure they are even on bothe sides.

2. Cut with dremel. (or tool you prefer)

3. Remove an jagged edges with dremel. I than use a sanding bit and cut the bottom and top sides of the cut to round them out.

4. Now sand ( I used 220 paper) edges to smooth out.

5. Heat edges to being back shine ( I used a propane bottle with a torch end on it at low setting which heats it quick) the shine will come back as they are almost at that point of melting. be careful not to melt them.

6. You are done.

04-07-2003, 06:44 AM
Your 400 has a really nice color scheme to it. I really like the black plastic:cool:

04-07-2003, 06:44 AM
Pic of the Maier stock with tape of how I cut mine. Tape how you prefer to cut them....

04-07-2003, 06:45 AM
Here you can see how jagged they are after cutting..

04-07-2003, 06:45 AM
A close up of the jagged edge

04-07-2003, 06:47 AM
After heating. They actually look more shinny they they came out and you can't notice any jagged edges anymore ...

04-07-2003, 06:47 AM

04-07-2003, 06:48 AM
front finished

04-07-2003, 06:50 AM
Riding Sunday.... You can see also taped off the bolts and painted them black before I took the quad out. Looks much better this way and hides the bolts...

04-07-2003, 06:51 AM
Before the cut...