Rear fender mount problem - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
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post #1 of 17 (permalink) Old 01-16-2013, 01:15 PM Thread Starter
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Rear fender mount problem

HI, I am a new person here. Hello to all. I have a 2003 VL800K3 that I just picked up and have been working on it. Got a new Kenda Kruz rear and have the wheel off and tire mounted and balanced. But, after reading some threads here, it looks like I could have just taken the 3 bolts out of each frame/fender support on each side of the fender and taken the whole unit off in one fell swoop. Problem is on the left side the three 10mm bolts are being stubborn PITAs. Anyone here have any good ideas on how to break the 3 bolts free without tearing up an 8mm allen wrench and the bolt heads?

Thanks, ~Jim
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post #2 of 17 (permalink) Old 01-16-2013, 01:23 PM
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Trying to understand, why are you taking off the fender rails to change the tires? If the bike is jacked up high enough there is no reason to touch the rails or fender. Unless you are adding bag supports or ghost bracket for the rails I would not undo the rails. The rule is one bolt at a time, hard to line up the bolts to put back.

But if you must remove them I would use a socket with a long pipe over handle loosen tight bolts.


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post #3 of 17 (permalink) Old 01-16-2013, 02:04 PM Thread Starter
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I dont have means to jack bike up high enough. It's on two 4x4s so I had to take off fender to remove tire/wheel assy,.

Are you saying use a 8mm allen in a 3/8 drive socket arrangement? All i have right now is a common 8mm allen wrench.

Would like to take the left fender support off to assemble it all back together then just slip the whole rear fender with supports, the whole assy, bock on the bike. Left 3 bolts are really locked on there. Right 3 bolts came out easily, which tells me someone followed the instructions in the service manual before maybe.

I want to take i t off like this one...Rear Fender with Lights Tag Plate Struts Off 2002 Suzuki VL800 Volusia | eBay

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post #4 of 17 (permalink) Old 01-16-2013, 02:29 PM
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Here is a thread that may help. But yes, try to borrow tools from someone who has the correct socket/allen head and a pipe, it will make your life a lot easier.

removing stubborn fasteners


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post #5 of 17 (permalink) Old 01-16-2013, 03:18 PM Thread Starter
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Thanks for putting up with my problem - using my head for something besides a hat rack I found the pipe which is the lever arm for my engine hoist and slipped it over the allen wrench and gained the necessary leverage to overcome the threadlock on those stubborn bolts.

Now on to read about the c90 final drive mods....
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post #6 of 17 (permalink) Old 01-16-2013, 03:41 PM
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+1 to what jendesigner said. Unless you thrive on misery, don't take the fender off.
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post #7 of 17 (permalink) Old 01-16-2013, 04:09 PM
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Quote:
Originally Posted by westslopevolusia View Post

Now on to read about the c90 final drive mods....
Go buy a jack


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post #8 of 17 (permalink) Old 01-16-2013, 04:16 PM
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Yes, I removed one of the bolts when re-doing my saddlebag and I had a ^&( of a time getting it back in there! What a PITA! I second the note about buying a floor jack for your bike. You will never regret it as it makes oil changes, cleaning or working on your bike so much easier.


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post #9 of 17 (permalink) Old 01-16-2013, 08:46 PM Thread Starter
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Thanks for all the input, and the advice is well received. I did however get the fender assy. put back together complete with fender supports fender and even a sissy bar. Not really that difficult. Just remember to leave the fender mount bolts (2 on each side) loose and then lining up the 6 support bolts (3 on each side) was a piece of cake. After the 6 support bolts are tightened up then go back and tighten up the fender mount bolts. Really not that tough.
But, it is a learning process. I read about this from one of the members here that did the exact same thing, and had no problem either. Old thread I found. Wish I could remember who it was, but I'll thank him here anyway.
Of course a jack would be nice. But money is tight, and you gotta do what you gotta do.
Maybe this will help someother poor lump who hasn't the cash for a jack.
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post #10 of 17 (permalink) Old 01-16-2013, 11:32 PM
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Just to add to the discussion many of the bolts on the bike will have blue loctite on them(the not so permanent kind). Although its not always necessary a propane torch works miracles on that stuff(must use a handheld propane torch and not Oxy-acetylene because the propane torch won't get hot enough to destroy the powder coat on the frame or blue the bolts but will release the loctite). I did this on my fender strut bolts and they came out with little effort. Before the torch I had to really bear down hard and a couple of the strut bolts and that involved a lot of cussing and cold beer.(ok the cold.beer had nothing to do with the situation at hand haha!) But the other four came out easy once I.heated them.
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