Fitting the DS front mudguards to my 500 ?

[Orcade-Ian]

Ted, years ago I bought a DS copy front guard for my blue 400/4 - I know yours was supposed to be genuine but although the 400 doesn't have rubbers and top-hats I had the same problem.  It was only on one side in my case and being reluctant to file the end off the stay, with the likely chance of rust forming very quickly, I eased the 'spot faced' section of the slider with the Dremel.  It's a solid lump, nowhere near the oil and can easily take a bit of dressing.

Ian

[Johnny4428]

Sorry Ted! I misunderstood the problem! Oops 😳 I wrongly thought it was just an alignment problem.

[McCabe-Thiele (Ted)]

Yes Ian that sounds the best way forwards especially as it now just one stay that is the problem.

DS have replied to the effect that some extra washers may be required on one side - was yours the right hand side like mine?

[Orcade-Ian]

Ted, I think it was the right hand side but that would only be a coincidence as mine was definitely a 400/4 copy - a bloody good one at that! Apart from that slight hiccup it was indistinguishable from the genuine one I still have on the red bike.  The blue bike went a few years back.  Looking carefully at your pic, it doesn't need much and could be easily disguised with a bit of light peening with a small rounded punch to look 'as cast' where it's ground out.

Ian

[McCabe-Thiele (Ted)]

Yes Ian it could be a coincidence but - I suspect that as the fork bridge only has the larger holes on the right side that needs the top hat arrangement this means the mudguard fitting is like an original 400 on the left side so any problems will be pushed over to the right.

If the stay end finish was as it should be there would be no issues imho.

Still it is what it is so I will do some fettling to make the errant right rear stay  fit when SWMBO allows me to sort it. Not keen on the DS idea to fit washers - I would need something like an 18mm o/d washer with a 6mm bolt hole would probably need to be 2mm thick to be an effective fix. I would then want to fit them to all four ends so it looked right - your solution looks the best way forwards methinks.


 

[Oddjob]

I would respectfully disagree Ian, if what I'm understanding you are saying is that in preference to grinding or filing the back of the stay down to suit the front you enlarged the recess in the fork slider to allow the stay to fit inside the enlarged recess?

If that's correct whilst I agree it's nowhere near the oil in the fork it is very close to the hole in the slider for the spindle clamp studs to thread into, any weakening of this area could result in the stud breaking out of the slider, especially under braking stresses. It's not something I would chance TBH. To me it's far easier to either use the original stays (if you have them of course and they are not rusty etc) or to grind or file down the back of the stay to match the front, I'd then paint the worked edge with zinc paint and apply a little grease to that area when mounting it.

I would also point out to DS that he consults with his supplier (can't be Honda as they'd have them made correctly) and ensure that any future orders aren't subject to the same fault. Just asking you to bodge it is unacceptable. To be sold in the UK it must be fit for purpose and these clearly are not. That fault would be a doddle to fix in manufacture, which proves they are going for profit and quantity more than quality.

[Bryanj]

Honda stopped making the 500 four mudguard years ago and superceded the part to the 750 part number, and whilst the later 500 had 341 sliders i suspect the early ones and thenon caliper side are cast very slightly different

[McCabe-Thiele (Ted)]

DS describe it as a genuine part with the below information.

"This was originally intended for the CB750K2, it is perfectly suitable for the CB500 FOUR. It may desired to fit washers to one side of the mounting stay as the 750 had 10mm mounting bolts as opposed to the 500 which had 8mm."

I did wonder are the 750 fork legs a different profile or diameter?
I will see what DS say in response to my question about the stay end finish.
If I have to I'm leaning towards trimming the end of the stay back as an alternative - an expensive option could be to have my original stays re-chromed if they are the same fittings elsewhere.

[Seabeowner]

The 500 (6mm hole) is only about 16.5mm wide on the stay at that point, The larger hole stays are about 19.7mm. The scooped out section on the 500 is thus smaller. On the 550F (341 forks (yes 750 type)) the scooped out sections come within 24.7mm of each other on the 500 it is nearly 31mm. (if you see what I mean)
I think choices are limited. Either use the old stays or I think you would OK to take out a little material.

[Nurse Julie]

"DS describe it as a genuine part with the below information."

This is the difference between Genuine and original parts. Original will fit easily, as its the correct part for that model, genuine will fit with fettling and do the job but it's not the correct part for that bike. Saying that, we've fitted 7 of these front mudguards and it's all down to manipulation when fitting them. I always had to help Graham by pushing or pulling or lifting a tad in different directions to get them to fit perfectly but it is achievable.

[McCabe-Thiele (Ted)]

I think that what I have done in getting 3 out of 4 stays to fit.
I ran out of time on the 4th as SWMBO was due back any minute so ran out of time.

My next window of opportunity will not be until the weekend - I do not want to risk Wendy's wrath if I am caught in the garage.  I'm sure having met Wendy you can identify with my plight Julie 😁😁😁

[Nurse Julie]

I think that what I have done in getting 3 out of 4 stays to fit.
I ran out of time on the 4th as SWMBO was due back any minute so ran out of time.

My next window of opportunity will not be until the weekend - I do not want to risk Wendy's wrath if I am caught in the garage.  I'm sure having met Wendy you can identify with my plight Julie 😁😁😁

😂 😂 😂 😂 😂 Wendy knows best Ted. Wait another week and then loosen off all the nuts and bolts and get Wendy to help you, it really is easier to fit it with 2 people.