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Einleitung
Balu Racing delivers a blank of the rear wheel cover. This has to be adjusted with a few steps.
How to paint the blank is not described here. Do not paint it before everything fits and you've done a test run.
This is the blank like you get it from Balu Racing. The end of the chain guard has been cut open already. It is delivered closed an can be cut open according to your needs.
Preparations
The opening for the braking rod has to be made with a Dremel or circular grinder. Picture 6 does not have have it, picture 7 shows the opening.
Now drill 2 holes in the cover. (picture 8, red circles)
Preview
The following pictures show the attachment to a swing arm that has been taken out of the bike. We only did this to show the procedure better, you do not have to do this.
Conversion instructions
Now the cover is going to be attached to a GS 500 swing arm with a SV 650 rear wheel conversion. Here a 160/60 Zr17 rear wheel tyre has been used.
For the conversion you need the GS on the main stand/working stand and the painted cover.
First you detach the left foot peg. To do so, remove the screws marked red in picture 3. Afterwards you remove the chain guard, the red circles in picture 4. Picture 5 shows how it should look now.
As we have to get to the brake rod screw (marked red in picture 6), we detach the right ffoot peg including brake pump and brake lever (red circles on picture 7)
Now we can easily access the screw to move the holder forward. To loosen the screw, you need to unbend the cotter pin (picture 8). Then take a wire cutter to it (picture 9) and pull it down at the bottom. Now you can unscrew the nut and hold the holder in your hand (picture 10).
Now you have finished all preparations to attach the cover.
Now you move the cover over the rear wheel and let it rest on top of the swing arm. On the side of the brake line you bend the holder open and remove the brake line from it (picture 11, red circle). Then put the cover under the holder. The piece of rubber/foam you got with the cover goes underneath the rear hole(picture 13, number 2) and gets attached loosely with a cable tie (picture 13, number 1). Now put the brake line under the holder again. Reattach the holder to the braking rod and realign it.
Use a new cotter pin!.
Now attach the cover at the front hole with another cable tie (picture 14).
Don't tighten the cable ties just yet!
Reinsert the screws of the chain guard, but do not tighten them completely yet.
Finally you have to align the cover and then tighten the screws and the cable ties. Make sure to move the cover as far to the front as ayou can before you tighten it. Otherwise larger tyres might grind on the cover.
Now you're done and it should look something like this.
Advice
Due to slight differences in each GS it can happen that the lower part of the original rear end unserside plastics hits the chain gaurd very mildy. We had about 2mm space, so we just cut it a bit.
We checked the cover both on a GS with a Wilbers rear suspension and a stock suspension. Nothing was grinding when riding solo or when pushing the suspension to the limit.
If you ride a GS with the underdampened stock suspension and have a pillion often, you might want to cut the cover as it can hit the plastics under the rear end otherwise.
An alternative would be to adjust those plastics.
On a lowered GS, we would recommend shortening the cover.
