400EX 250R Hood Install
Having new aftermarket plastic and a new oversized gas tank really helped us on this mod. We first bolted up the front finder to the larger tank. If you are going to be using your stock plastic then I would suggest not unbolting your front plastic from the bike. We did not bolt up the plastic to the bike but towards the end we found that if we had the process would have been a little cleaner. The reason for this is because once the finders are bolted to the bike the finder will take its true shape. An unbolted finder will be close but is still a little warped.
First do a rough cut on the finder to remove the stock
Take your new hood and drill 2 holes in the lower factory
Lining the hood up and best you can transfer the holes to the
With the hood in place and temporarily fastened we can measure
what needs to be cut on the upper part of the finder to make the hood sit flat
on the finder as best we can. We opted not to cut the lower finder due to the
complexity of the cut and the mounting options. We wanted to keep it as clean as
Our second mounts would use the factory hood fastening
locations already on the finder.
Because the hood sat so high off the finder mounts we needed
to heat the plastic mounts and mold them upward to get them closer to the hood.
Once this was done we were able to transfer these mounting
holes to the hood and mount it up.
After checking for fitment and clearance we found that the
hood did not follow the contours of the finder closer to the top. Again with a
B.B.Q. grill lighter we heated up the plastic from the bottom and molded the
plastic to the desired shape.
After the hood is completed clean up all the cuts with some
sand paper and heat. Here is the completed install of the hood.