Fender Riser Modification - Kawasaki Versys Forum
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post #1 of 8 (permalink) Old 06-09-2019, 12:09 PM Thread Starter
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Shared this a few times with members on FB and advrider via private message. But was ask to make it public. I’ve made a template for a custom fender riser. For those who want to raise due to larger tires without having to go to the extremes I have. They are made from thin aluminum you can find at any hardware store. My suggestion as a SS crossover brake-line be expensive. I suggest to just use good quality zipties and secure them to the stock mounts. That’s what I did at first. This all cost me no more than $30, the biggest source is the washers and nuts needed. You can also follow me on Instagram under adventurestan. Any questions just let me know and I’ll be more than happy to help. Also been thinking of mass producing these but that’s up to the market. I’ve also made a motocross fender mount and templates as well. If anyone is interested.
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16', Versys 650 LT, Black w/ modifications
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post #2 of 8 (permalink) Old 06-10-2019, 05:29 AM
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I must warn you about aluminum: it will not survive the fatigue from that weight on that unsuspended area.
It's a very high stress area.

In fact my simple alu rear rack broke from fatigue. Imagine the fender detaching while riding... perhaps taking away the brake line...
You need to do that bracket with stainless steel (or galvanized steel).
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post #3 of 8 (permalink) Old 06-10-2019, 11:27 AM Thread Starter
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Quote:
Originally Posted by dddd View Post
I must warn you about aluminum: it will not survive the fatigue from that weight on that unsuspended area.
It's a very high stress area.

In fact my simple alu rear rack broke from fatigue. Imagine the fender detaching while riding... perhaps taking away the brake line...
You need to do that bracket with stainless steel (or galvanized steel).
Appreciate that insight. I tested it on many occasions in the smoky mountains and in very rough terrain and it never budged. I also used the suspension and didn’t baby it to test it. There’s also other Versys riders who have used aluminum in their modifications with great success to include motocross fender mounts. And they put their Versys’s through more than I have. I appreciate the feedback.

16', Versys 650 LT, Black w/ modifications

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post #4 of 8 (permalink) Old 06-10-2019, 12:42 PM Thread Starter
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UPDATE - Just took some pieces to be cut from my templates for my motocross fender kit that I’m developing/testing. I’ll keep updates coming.

16', Versys 650 LT, Black w/ modifications

Last edited by Atalanta89; 06-10-2019 at 04:36 PM.
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post #5 of 8 (permalink) Old 06-10-2019, 01:09 PM
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Quote:
Originally Posted by dddd View Post
I must warn you about aluminum: it will not survive the fatigue from that weight on that unsuspended area.
It's a very high stress area.

.
I work with aluminium alot on mods on my Kawi and my electric bicycle and many metal related home projects. So easy to work with,light,doesn't rust.I disagree, I would use aluminium for this task.Think thicker than the applicable steel plate that you would use and its still alot lighter than steel. I would use 3/16th inch plate, maybe 1/8th I would guess. Not much weight bearing or torsion,just vibration. Our 650 right swingarm is made from ALU I believe. Look at mid level bicycles....everything metal is ALU alloy, frame,crank.Cut down weight, get more energy. Now theyre onto Carbon fibre. I would love to see a Versys 650 thats 50 lbs lighter,up high mainly.....thats something I would pay for!
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post #6 of 8 (permalink) Old 06-10-2019, 01:33 PM Thread Starter
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Originally Posted by jaaklucas View Post

I work with aluminium alot on mods on my Kawi and my electric bicycle and many metal related home projects. So easy to work with,light,doesn't rust.I disagree, I would use aluminium for this task.Think thicker than the applicable steel plate that you would use and its still alot lighter than steel. I would use 3/16th inch plate, maybe 1/8th I would guess. Not much weight bearing or torsion,just vibration. Our 650 right swingarm is made from ALU I believe. Look at mid level bicycles....everything metal is ALU alloy, frame,crank.Cut down weight, get more energy. Now theyre onto Carbon fibre. I would love to see a Versys 650 thats 50 lbs lighter,up high mainly.....thats something I would pay for!
The 1/16th inch plate is what I used. It worked great for the fender risers. I used the stock bolts and bought bolts to match for the two extra holes for mounting. A simple 10mm wrench and you good to go. Could’ve went thicker but it worked.

16', Versys 650 LT, Black w/ modifications

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post #7 of 8 (permalink) Old 06-10-2019, 02:52 PM
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I used 1/8" aluminum for the fender-risers I fabbed for my '08 and '09 V650s - and they've lasted VERY well! Close to 80,000 miles of use, on my '08.
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post #8 of 8 (permalink) Old 06-10-2019, 04:38 PM Thread Starter
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Originally Posted by fasteddiecopeman View Post
I used 1/8" aluminum for the fender-risers I fabbed for my '08 and '09 V650s - and they've lasted VERY well! Close to 80,000 miles of use, on my '08.
Very nice. I’m digging it.

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