Before:
Remove the seat and unhook the 4 bullet connectors for the turn signals and the molex connector for the taillight
Remove the 2 bolts attaching the fender to the grab rails and lower bolt from the tail to the loop of the subframe to remove the tail
Stuck the whole Baja Designs fender in for a test fitting. Looks OK, but the concave part in the middle holds the top of the fender too high off the cross piece of the subframe. Modifications will be required to the tail, and a loop-ectomy is also in order.
Time to cut the Baja tail. I used a air-powered cutoff tool (like a huge dremel), but you could use a saw, or even a knife if you're careful and patient.
View from the underside of the new tail after modifcation (I ended up cutting the sides of the V shape about 1.5" shorter by the time I was finished)
Side view of tail - I cut the sides of the fender off until I was about .5 inches from the flat pieces where the signals will mount
Top view of Baja Tail (I still haven't shortened the sides of the V yet)
Time for some a tasty beverage
I removed the lower bolts from the rear fender and lifted it with a pair of leather gloves. Then I wrapped it in a wet towel to protect it from debris and sparks. It's loop-ectomy time...
Oh, I can't believe I took a cutoff tool to one of my bikes!
I removed the loop and braces right on the welds. I'll get a brace welded in place just to be on the safe side.
Side view of test fit - you can see the loop laying on the ground
Close-up showing how the notches in the Baja Tail fit over the subframe now.
Rear view of test fit
Screwed in and ready to finish the wiring
I bought a set of Motrax turn signals to finish off the tail, as I felt the stockers were too big and bulky. The new signals cam with very short leads, so I opened up the old turn signals and found that the wires were attached to them with some very small spade terminals. I removed the wires and cut them about 1.5" below the spade terminals and joined them to the new signals. I could also have extended the leads from the new signals, but I could not find bullet connectors to plug into the bike wiring harness that fit tightly enough to make me happy.
Finished!