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When I tried to get the Swingarm spools on the Ninja 250R the first time, I found out that the saree guard won't let you do that! So I decided that I will remove the saree guard whenever I got a chance. My tail cover changes and applying paintguard stickers were my priorities, so I left the saree guard and the front number plate removal for the last. Today was a beautiful sunny day and pretty much open for me to do anything, so I resolved to make it a full Ninja 250R DIY day.
Removing the saree guard is fairly simple, provided you have the right tools and replacement flange bolts after you take off the metal structure out. So here's how the original deal looks like, with the guard on.
So as you can see, there are three bolts which attach the guard to the swingarm. Two are small 8mm head ones inside a hard to reach recess, and the third one is at the bottom, which incidently is the swingarm spool thread.
You would need a T-spanner with a 8mm socket, ordinary ones cannot reach there. This tool would prise out the two hidden bolts, and a regular 10mm spanner will make short work of the exposed bolt below.
Voila! The saree guard removed, making the bike a little lighter.
Now, to put the plastic chain cover back on, you cannot reuse the original 8 mm bolts which came with the saree guard since it will slip through the hole. I had a couple of 10mm non-flanged bolts lying around, so I put those on. While it fit well in the rear, in the front, it was passing through the hole (picture) above. The pictures below shows how I took care of that problem.
I had to 'borrow' a flanged bolt (bolt with a bigger base below its hex head) from my Royal Enfield, which fit perfectly! And I swapped the smaller head one and screwed it on my RE. But only for a few hours - in the afternoon, I went to an auto store and picked up 4 flanged bolts with 10mm heads. So I removed the non-flanged bolt from the rear swingarm and put in the ones I bought.
I recommend using 10mm flanged bolts after removing the saree guard. I noticed xinfii (Praveen) using metal washers with the existing saree guard bolts, and they don't look cool at all. Sorry Xinfii!
Once the saree guard comes out and the chain cover is securely attached, screw in the swingarm spools on both sides using a 8mm Hex wrench (allen key).
Easy!
Removing the saree guard is fairly simple, provided you have the right tools and replacement flange bolts after you take off the metal structure out. So here's how the original deal looks like, with the guard on.
So as you can see, there are three bolts which attach the guard to the swingarm. Two are small 8mm head ones inside a hard to reach recess, and the third one is at the bottom, which incidently is the swingarm spool thread.
You would need a T-spanner with a 8mm socket, ordinary ones cannot reach there. This tool would prise out the two hidden bolts, and a regular 10mm spanner will make short work of the exposed bolt below.
Voila! The saree guard removed, making the bike a little lighter.
Now, to put the plastic chain cover back on, you cannot reuse the original 8 mm bolts which came with the saree guard since it will slip through the hole. I had a couple of 10mm non-flanged bolts lying around, so I put those on. While it fit well in the rear, in the front, it was passing through the hole (picture) above. The pictures below shows how I took care of that problem.
I had to 'borrow' a flanged bolt (bolt with a bigger base below its hex head) from my Royal Enfield, which fit perfectly! And I swapped the smaller head one and screwed it on my RE. But only for a few hours - in the afternoon, I went to an auto store and picked up 4 flanged bolts with 10mm heads. So I removed the non-flanged bolt from the rear swingarm and put in the ones I bought.
I recommend using 10mm flanged bolts after removing the saree guard. I noticed xinfii (Praveen) using metal washers with the existing saree guard bolts, and they don't look cool at all. Sorry Xinfii!
Once the saree guard comes out and the chain cover is securely attached, screw in the swingarm spools on both sides using a 8mm Hex wrench (allen key).
Easy!
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