XR400 Side panels
 

Danial asked how I fitted the XR400 side panels - so for the benefit of anyone else who is interested here goes....

The XR400 panels were fiddly to position and modify to shape, but the final installation was easy. The first bit is the hard bit.

General overview.. The XR4 panel each side is bolted using the two XR4 panel holes at the front, and cable tied to the frame rail at the top rear..... The hard bit is cutting out a shaped hole in each XR4 panel for the grab rail to pass through, and an indent at the rear for the same reason....
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General installation from the underside on Right....

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Step 1 is to remove the pillion footrests, seat and grab handle each side, and bolt the XR4 panel inplace using its forward bottom mounting hole and the top hole in the pillion footrest mount. I used a threaded panel clip pushed over the pillion mount to provide something to bolt into (these are common in the car world and can be had for a few cents at the local auto store)...

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Once bolted in place at the bottom front, I rotated / adjusted the XR4 panel so that the top crease in the XR4 panel (parallel to the top edge) was lined up with the general run of the bodywork on the Tenere. I checked this by reinstalling the seat temporarily and adjusting the panel position until it looked right...

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The crease sort of follows the line of the top of the airbox and the underside of the seat.

Then I marked the Tenere frame under the centre of the top front XR4 panel hole, and drilled a suitable hole in the frame (this is in the area of a stiffening web and a second hole - about 6mm diameter - is no problem for the frame). Then used a similar panel clip and some spacer washers to bolt the XR4 panel at the top front (the yellow thing in the photo below is a bunch of washers to the correct thickness bound together with PVC tape so that they don't all fall on the floor when I take the panel off!)...

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Then I offer up the grab handle and with a felt pen mark around the end of the grab handle where the hole in the panel has to go and the rear indent has to be cut out. This is fiddly as the grab handle doesn't sit in its final position with the XR4 panel in place and some estimation is required. Then cut out the holes in the XR4 panel well within the marked areas - I mean 30% of the finished size hole - this means if it is in the wrong place it can be moved without overcutting any part of the panel. Progressively offer up the grab handle, remark and cut out bigger amounts of plastic until the right shape hole is achieved. Once the grab handle can be mounted clear of the XR4 panel, reinstall the XR4 panel and bolt up the grab handle for the final mark out and cut. To make the "factory" looking clearance around the grab handle, I held a pen against the grab handle and perpendicular to the XR4 panel and then traced round the handle to give a line a constant offset from the handle. Make the final cut and clean up any rough edges and now go and do it on the other side!!!..... You can see the final hole shape in the panel in the shot below (I could have cut it out more easily by removing material right to the top of the XR4 panel, but felt that the panel would have been weakened if the top edge had been cut, hence I persevered with a small hole)....

http://i1009.photobucket.com/albums/...s/DSC06410.jpg

In this shot you can see the indent in the back end of the XR4 panel which also needs to be cut out on both of them to clear the grab handle...

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The left hand panel had heat reflective material stuck to the inside surface (can get this from most bike shops in self adhesive sheets), and the SR racing exhaust comes with very large hose clamp / jubilee clip which when positioned as in the photo keeps the XR4 panel from touching the hot exhaust can. Worked fine on my bike for 30,000kms.....

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Here's a shot of the cable tie to the back top of each panel around the frame rail to finally hold everything in place.....

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Hope this is useful.:icon_lol::icon_lol::icon_lol: