Body panels and mudguards

Body panels are the plastic side covers, tank covers, front and rear mudguards and, on scooters, the large panels and floorboards. They are held by screws, bolts, rubber grommets and plastic hooks or tabs.

What it does

Panels keep water, mud and stones off the rider, the engine and the electrics. Mudguards stop the tyres throwing water up. Panels also protect wiring and fuel parts. Hooks and tabs break easily if you pull a panel off the wrong way, and then the panel rattles.

Signs it is worn or failing

• Rattles: Rattling from panels, mudguards or the seat.
• Cracked or missing panels after a fall: The bike has been dropped or crashed.
• Water reaching wiring under a broken cover: Electrical faults after rain.

When to replace it

Replace a panel that is cracked through a mounting point, a mudguard that touches the tyre, or a missing cover over electrics. Small cracks away from mounts can often be repaired with plastic welding.

What to match when buying

• Make, model, year and colour code. Panels from a different year may have different mounting points.
• Buy the grommets, clips and screws as well; old ones are often broken.
• Cheap copies may not line up with the mounting holes; compare photos with your bike.

Fitting notes

• Remove panels in the order in the manual; find all screws before pulling. Do not force hooks.
• Do not overtighten screws into plastic.
• See Find and fix rattles and Check chassis fasteners.

Reference (K-Light 125)