(Provided courtesy of Kyle Johnson)
 
 
 
 

Well I did it! Thanks to Pete and others for giving me the courage to try it myself (because I dont trust the twits at the dealership anymore than I trust myself!) If you want it done right, do it yourself! Who cares more about the work done on your bike? You or the twits? On my 1999 900RR the body panels are in three pieces per side so it was pretty easy to just remove the middle section which is the one that covers the bolt that the Intuitive Frame slider will be attached to. Im sure some of the bikes that are one piece per side will be a bit more work, but this method should still work out. Have Patience! Also, my RR does not have any of that heat shield foamy stuff on the inside of the panels so I used Play Doe as a 'marker' for the bolt head to find the center of what would be the 2" hole in my bodywork! It worked GREAT! Ok, I will add text to the bottom of the following pictures as a walk through style installation description which will be better than me just rambling on.

PICTURE 1: I have removed the factory upper motor mount bolt and I'm holding the replacement bolt that came with the sliders. Its longer of course.... This is where the slider will be bolted to the bike.

PICTURE 2: Here is the back of the body panel with the pretty purple Play Doe on it; ready to put in place to obtain the bolt mark...

PICTURE 3: Here the bolt is partially installed. I left it out far enough to give me a good indication mark on the Play Doe. Dont leave it too far out, you need to be able to put the body panel in its correct position without actually touching the bolt against the body panel.

PICTURE 4: VIOLA!! Not only did I get a perfect bolt impression, the Play dough changed colors too! (Just kidding, the green just photographed better)

PICTURE 5: I drilled the pilot hole right in the center of the bolt mark. Accuracy is important here!

PICTURE 6: Here is a close up showing where I drilled the pilot hole... RIGHT IN THE CENTER of the bolt mark!

PICTURE 7: Here is the same shot as picture 6 after removing the Play Doe. Nice little pilot hole eh? So far so good!

PICTURE 8: Here is the front side of the panel with the pilot hole. You must drill the actual 2" hole from the front so that you get a smooth entry into the plastic and you dont push the decal stickers from the backside. Its just cleaner to start from the outside ok?! Trust me!

PICTURE 9: THE SCARY PART!! line up the Mandrel or center "guide" drill bit of the hole saw ON the pilot hole. Make sure the body panel is secure. (Wife/girlfriend comes in handy here even though she might be yapping about how crazy you are for drilling holes in your body parts etc. etc. Ignore her and relax!) DO NOT drill the hole at a crazy high rpm! Its not necessary and will only create heat that melts plastic! Nice and steady -firm pressure- not to much speed or pressure though. NOTICE the wood block under the body panel? Good.

PICTURE 10: PHEW! its over.. and it even looks good!

PICTURE 11: Here I used my handy wizard (same as a Dremel but I like the grip better) to 'debur' the edge of the hole. Be gentle and take your time. You want the rotation of the sanding barrel to be 'pushing' downward into the hole in relation to the edge you are sanding for the same reason you drilled from the outside. Get it?  You can also use a black magic marker afterwards to finish the inside edge of the hole. I did this but forgot to get a picture... You can figure it out. Magic Markers come in a variety of colours to suit you fancy.

PICTURE 12: Here it is!! See the faint yellow edge of the hole? That is why I used the black magic marker after this shot was taken to finish the edge up. Worked well and the marker is permanent.

PICTURE 13: The Finished product! YAAA! Total success! And the satisfaction that I did it myself! Notice the edge is nice and smooth and black? Now just do it all over again on the other side! DONT EAT the Play Doe!             GOOD LUCK!

Extra Special thanks to Kyle Johnson for providing the tutorial above!

 

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Last modified:  May 22, 2000