SG400 Front Fender and Tank Swap
Tools needed:
Phillips head screw driver
8mm socket
5mm Allen
4mm Allen
Place the bike on side stand, or if available place on motorcycle lift
Remove the seat using the seat release on left side cover
Unclip this line holder
Remove 3 fender bolts on the left side, 5mm hex head driver
Repeat for right side
Using a small screw driver remove 4 phillips head screws holding the fender to the bracket
Repeat on left side
Remove clip from old fender by squeezing the prongs
Install clip on to new fender
Install new fender by screwing it to old support bracket, 4 screws on each side
Line up fender support bracket
Install (3) screws using a 5mm Allen
Place lines inside holder
Remove left side cover by removing two 5mm hex screws on top and bottom of side cover
Repeat for right side
Place left side cover on top of frame to avoid disconnecting the seat release
Remove 5mm hex head from rear tank mount
Once tank has been removed, drain the fuel and remove gas cap using 4mm Allen
Next place the tank upside down in a soft surface to install fuel pump and fuel gauge
Fuel gauge
Fuel pump
Install (6) 8mm bolts in an alternating pattern, carefully tighten down evenly (firm, but do not overtighten)
Next tighten fuel gauge with (2) 8mm bolts, tighten carefully and evenly (firm, but do not overtighten)
Install old gas cap in new tank with (4) 4mm hex head screws
Install Heat Shields
Install tank, plug in 2 vent hoses, fuel line and both electrical connections, one on the right and one on the left
Remove rubber grommets and install on new tank
Reinstall side covers with (2) 5mm hex head screws on the top and bottom of side cover
Install rear tank mount screw using 5mm Allen
Install seat
