8.5. FRONT MUDGUARD

You can choose from two types of front mudguards. The classic package has the large mudguards tight against the front. The sports package contains “cycle-wings” which are mounted to the stub axle.
For the classic package, the following applies:
The placement and mounting of the mudguards is easiest with some extra hands. First, make sure the mudguard looks fine before you connect it. If necessary scour and polish the seam (see picture). If the mudguard is already assembled, it is difficult to reach. Download a manual for the scouring and polishing here.

Classic front mudguard:
- Hold the mudguard against the front.
- Make sure the bottom of the mudguard is equal to the bottom of the body/front.
- Shove the mudguard against the notches for the rocker covers  in the front.
- Remove unwanted polyester from the mudguard if this causes a poor connection at the notch of the rocker cover or at the bottom of the body.
- Make sure the wheels can turn in all positions.
- Draw the contours of the mudguard with a marker.
- Drill nine holes, proportionally divided, at ca. 2 cm within the line you have drawn. Check the bottom plate! The back hole you will drill could come close to it.
- Make sure the front is also fastened with one of these holes.
- Drill the holes (Ø6.5 mm) in the front.
- Let an assistant hold the mudguard against the body again, and drill the holes through the mudguard from the inside.
- If you want to mount rubber beads between the mudguards (see chapter 5.1), put the mudguard on its side and glue the rubbers to the polyester. This will be an easy job if you use clamps, see picture.
- Glue the rubber beads neatly around the corner and make notches for the attachment holes.
- Fasten the mudguard all around with M6x20 bolts and sheet-metal rings. The bolt that also goes through the front is a smaller M5 bolt.
Mudguard holder:
- Now put the mudguard holder (RVS bars) between the body and the mudguard behind the wheel. The mudguard holder prevents the vibrating of the point of the mudguard and puts it in the right shape.
- Do not mount the mudguard holder (strips) as close to the front as possible, as the wheel could then hit the mudguard holders during wide angles. See picture.
- Push the mudguard to the outside (using the mudguard holder) until it becomes the correct shape, in line with the back mudguard.
- Bend the mudguard holder down on the body’s side so that it can be attached more neatly.
- Drill holes and fasten the mudguard holder with bolts and small rings. Bear in mind that the bracket should not protrude at the bottom of the mudguard.
- Determine the highest point of the front mudguard and drill the holes for the indicators and use the indicators as moulds.
- Mount the indicators.
- Stick the wiring under the mudguard through the front and connect it.
- Glue the wiring with Sikaflex against the polyester.

For the cycle wing front mudguards of the sports package, the following applies:
- Dismount the wheel.
- Mount the RVS bracket on the stub axle. First, unscrew the old bolts and use the new M7 socket caps with a hardness of 10.9. Do not forget to use the included collar for the back bolt.
- Mount the wheel and remove the carjack.
- Ensure that the distance between the wheel and the RVS mudguard bracket is 10 mm at both bars. Bend the bars of the mudguard bracket with an adjustable-joint plier if the distance is not right.
- The distance between the back of the mudguard and the road should be 120 mm. The driving height should be adjusted first.
- Fit the mudguards onto the bracket. Make sure the centre of the mudguard is put in the centre of the wheel. Bend the mudguard bracket or polish some polyester off the mudguard if this is not the case.
- Roughen the strip of the RVS bracket and the polyester by means of sandpaper.
- Scour this strip and the polyester mudguard, preferably with acetone.
- Glue – preferably at room temperature – the mudguards on the strip with Sikaflex 260! Use enough glue since there are two different materials with a different coefficient of expansion.
- Fasten the mudguards with tape to avoid movement.
- Let everything dry for at least 48 hours before you hit the road.
- Put the special indicators for “cycle-wings” on a suitable position in the front.
- Connect the wiring for the indicators.

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