Serco Plastics

[racingcee]

Any one fitted the 09 rear fender on a 04 250? cheers

[crashandburn]

yes i am in the process of doing that now,i was told that they fit with a little modification however it seems to be turning into a larger task than anticipated.

firstly i found that the petrol tank is a different shape to the newer models so i shaved the new one to butt up against the tank and match the front mounting hole,the next problem is the rear frame mount which has to be cut off and refabricated to suit the new shaped mudguard which bolts through the top surface as opposed to the old one which bolts through the sides.

my next problem is with the airbox it seems to be to wide and is forcing the mudguard over to one side,as i am still tackling this problem i can't comment on the outcome yet.

remedy;

buy newer style airbox,make new airbox,try to alter original airbox.

hope this gives you an idea of whats in store good luck

[chewy]

dont really know what this is but plastic can be "remoulded" a bit with hot air gun and subtle pressure..wort a thought ?

[racingcee]

cheers, i was pretty sure i would need to mod the frame, but as its going in to the coaters to bet the black treatment i was cool with that, airbox could be a issue, i think the 09 airbox is coming in about 50 notes, i had set a budget of 200 notes for coating and fresh plastics and graphics.. and thought i might as well update the looks a bit if i could, 04 and 09 plastics are more or less the same money same with graphics, i can get 09 graphics kit made to suit the later fender and the 04 tank ok, guess its just the airbox issue, did you take any photos of the subframe mod.s? cheers

[copemech]

The '05 mudguard should go directly in silver, Those graphicks were nice as well!

Careful to easily use heat and such on removing origilal tank graphics, as if you yank it it will take off everythinng !

U are screwed!

[crashandburn]

just about finished converting my 04 sherco to take 08 style plastics but i think it is probably easier to buy a later model unless you really are up for a challenge.

firstly i had to alter the rear frame because the new mudguard bolts through the top.

the 04 petrol tank is a different shape so the new mudguard needs to be trimmed at the front edge to match against the tank(approx 10mm off from center tapered down to match tank and line up with front mount hole.

because of this alteration the mudguard sits slightly further forward and up leaving a gap approx 10mm at front of airbox and exhaust tapering away(does not look too bad but the standard mudguard sits flush against the air box and exhaust, no gap on side)

trimming the mudguard means the sticker will also have to be trimmed so this will alter the flow of the design slightly.

next problem was the airbox,got all the mudguard sorted and went to fit it but airbox would not go in,came to the conclusion that the 04 mudguard was wider than the 08 one.

i had to cut the tail end of the airbox down which tucks under the mudguard lip and then starting near the top front of the airbox i cut it all the way along the top round the tail and back down to the front so all that was keeping the box together was the front part which faces the motor.Then a section has to be cut out (tapered to 10mm at tail end)thus narrowing the airbox to fit inside the 08 mudguard.

once you are happy with your cut the air box can the be plastic welded back together(tricky but can be done with soldering iron)

there should be some you tube footage for plastic welding if you have a search

also you need to make a spacer to go between the petrol tank and front of rear mudguard as there is a gap approx 10mm(where bolt goes through for it to tighten)

this is where i am up to at the moment in for a penny in for a pound,hope to have bike finished in a couple of weeks

[ham2]

just about finished converting my 04 sherco to take 08 style plastics but i think it is probably easier to buy a later model unless you really are up for a challenge.

firstly i had to alter the rear frame because the new mudguard bolts through the top.

the 04 petrol tank is a different shape so the new mudguard needs to be trimmed at the front edge to match against the tank(approx 10mm off from center tapered down to match tank and line up with front mount hole.

because of this alteration the mudguard sits slightly further forward and up leaving a gap approx 10mm at front of airbox and exhaust tapering away(does not look too bad but the standard mudguard sits flush against the air box and exhaust, no gap on side)

trimming the mudguard means the sticker will also have to be trimmed so this will alter the flow of the design slightly.

next problem was the airbox,got all the mudguard sorted and went to fit it but airbox would not go in,came to the conclusion that the 04 mudguard was wider than the 08 one.

i had to cut the tail end of the airbox down which tucks under the mudguard lip and then starting near the top front of the airbox i cut it all the way along the top round the tail and back down to the front so all that was keeping the box together was the front part which faces the motor.Then a section has to be cut out (tapered to 10mm at tail end)thus narrowing the airbox to fit inside the 08 mudguard.

once you are happy with your cut the air box can the be plastic welded back together(tricky but can be done with soldering iron)

there should be some you tube footage for plastic welding if you have a search

also you need to make a spacer to go between the petrol tank and front of rear mudguard as there is a gap approx 10mm(where bolt goes through for it to tighten)

this is where i am up to at the moment in for a penny in for a pound,hope to have bike finished in a couple of weeks

Shall we be getting it dirty Mr. Colley?

[copemech]

Why would you want to do this?

[tony27]

Masocistic streak?

[crashandburn]

you have got to be creative to understand

[ham2]

Steve is the 'Trials Department' of Orange County Choppers.

He's a bit of an artist with the spanners/grinder/welder/spray-gun..you name it....the original engine whisperer!

I know of a very unhealthy quarry where you could undo all that good work in one session