G'day all
Decided that after ordering my Tail chop kit from Monsterparts about 6 months ago, I'd better get it fitted,
here is a brief look at hacking the tail off my 2007 S2R 800
Chop Kit from Monsterparts:Competition Werkes Monster Tail-Chop Kit, I looked at a few others but decided this kit was the kit for me, room for the number plate light, and included all bolts, nuts and decent instructions
I painted the Kit Black with a quality self priming Paint.
Tools RequiredSocket Set and Allen Driver Set
Assorted allen Keys (Allen drivers can't get into some tight corners)
Measuring tape and Marking pen
Wire cutters and Zipties
Hacksaw and some assorted small files
Loctite and some self priming paint (black)
Soldering Iron and solder (optional, I have modified some of my wiring so I had to cut and join some wires)
Soldering Iron with Plastic cutting tool or a small saw (To cut some plastic under the seat)
The offending article!
Remove the four nuts from under the tail, Flip it over and remove your Tail light, Indicators and Number plate light (I have a CA Led Taillight and LED Number plate light)
Clear all your wires away from the Tail section, it should be now bare and nothing near it at risk of being cut or damaged, because soon we start cutting!
Time to Measure 6.5 Inches from the end of the Tail, I mark this with a permanent pen, I also put some clear tape around the paint in case the saw moved or slipped, I would hack at the tape, not at the paint!
Again double check your measurements! and to be safe check again. Then step back and make sure all your pen marks look to be in line.
Now Grab your Hacksaw (I know some people will use Grinders, Cut all's, Plasma Cutters, C4, Etc, I'll leave your choice of weapon up to you)
Do Not use a Pipe Cutter, this will Damage and Chip the Paint on the Frame
After about 10 Minutes of Hacking and Destroying, A trimmed frame, I now grabbed a couple of files and tided up the edges to make them nice and smooth, I also grabbed a Vacuum cleaner and cleaned out all the metal filings from the frame, you will also notice the Tarp covering the rear wheel and Chain, I figured metal filings all over the Chain and getting on the Shock would not be a healthy Idea for there longevity.
In this photo I have painted the bare metal with a black anti rust paint to seal everything up and I have installed the Caps from the Tail Chop kit, I have used a little loctite on them to lock them in place, they are a snug fit, but with all the vibration I think they would work loose without a little help from the Loctite.
I have now got the Tail chop bracket in place and secured using the longer bolts that come with the Kit, I use a little Loctite (Blue) to secure them in place.
Here's the Underside of the Replaced Bolts, This is the Before shot, In the Kit I bought these are replaced with a longer bolt and I also put washers under the bolt heads, I had none on the original bolts from factory (as shown here) there is another just out of shot on the left.
This Shot shows the longer threads poking through and I have secured the Tail light back in place.
NOTE: when running all of your wiring, make sure they will not get caught in the latch or will not pinch under the seat when it's locked in place.
This shows now shows the Number plate light back in place and wired in, again Loctite was used on the bolts and screws to ensure they would not come loose and fall out.
Alright, the end is near,
well done if you've made this far!!
This is the bracket in place for the Indicator, you might have to bend this up or down a little to get it sitting level. again watch your wire routing to make sure it can't be cut, nicked or crushed.
Nylock nuts are used here to lessen the chance of them vibrating loose.
This is the almost finished wiring, I just have to secure the Indicator wires, the excess wire has been coiled up incase I have trouble with the local
and he wants the Tail put back on, at least I won't have to a heap of extra soldering and joining to do.
And here it is all done..... Well, Not Quite one more Job to do yet, we have to modify the Seat, but it looks good so far, I have to say I'm amazed at how heavy the removed piece of frame and plastic are!
The seat posts at the rear have to be modified or removed, I decided to remove them, I used a soldering iron with a plastic cutting attachment to cut them off.
If you choose to melt them off like I did, do it in a large well ventilated area, I had a pedestal fan sitting off to my right running at full power while I did the work to ensure no smoke or fumes could reach me.
Well after all the saga, we have completed the Job, I just to now have to play around gently bending the brackets to get them nice and snug up against the seat, but I'll do that another day, I'm going to have a
And after making through this Tutorial, I think you need a
as well. Go on, you deserved it!
