updating bodywork

[col]

My wife has a N-reg 500e (s model) and i was wondering if its possible to upgrade the bodywork to that of a newer model, I was thinking something from an  K2 model.
I know it'll mean new tank/seat/side panels and tail light but i need to know if its possible without to much faffing about.
Also if you can think of anything else i'd have to alter please let me know.

[RVertigo]

It can be done, but it's not easy.  It involves welding the correct mounts for the new plastic.

If you search around on the forums, you'll see that a couple people have done it...  But, it's not common because it's not that easy...


But, it can be done...

[The Buddha]

An 89-00 to an 01-02 look is very very little welding. The only welded bit I believe was the sissy bar piece. I made some nifty bent stainless sheet metal brackets and used them as grommet carriers. Yea You'd have the old style seat latch and the foot peg carriers grommet holes to cover up though. and yea the body set has a hole in it for the new type seat latch. You gotta get either that latch or cover that up somehow. but its almost straight bolt on with very very little welding. Have fun making brackets though. I used some thick ass stainless plate. Maybe using steel or aluminum is better.
Cool.
Srinath.

[LimaXray]

I don't think the mounting points for the tail plastics will line up.  A guy got ripped off over in the UK buying what he thought was a '02 which was really a pre-'01 with '02 tail plastics.  The mounting points were a couple inches off so the tail plastics were held on with wire ties.  Also, IIRC the grab handle didn't line up with the seat or the plastics leaving a big gap between the seat and the grab handle.

[dgyver]

I am in the process of fabricating the brackets to install 05 tail plastics on a 97. I am not planning on welding anything to the subframe. I will either bolt the brackets to existing holes or rivet to new drilled holes. The only welding will be to fabricate the brackets themselves. I repainted the frame prior ot obtaining the newer plastics, so I do not want to repaint it again. I do have a 05 salvage frame to model from. I have not decided what I am going to do to the 05 frame yet, so I do not want to alter it.

[Chuck]

I'm not a structural engineer, but does the frame like having holes drilled in it?  I suppose if they're small holes...

[dgyver]

An 1/8" is not going to compromise the integrity of the subframe. Plus there are plenty of holes already there and these are going to be in the brackets themselves. Heck I applied over 2 tons on a subframe to straighten it and it barely moved.

[Chuck]

Oh.... duh.... subframe.  That makes me feel better already.    I forgot we are talking about tails here.  It would probably be okay on the main frame as well, but hey, I'm paranoid.

[The Buddha]

I didn't have to drill into the sub frame at all. I made clamp on style brackets for grommets, slapped grommets on them and fit it. Actually someone on here bought a set of tail brackets from me - who - Jiggersplat someone else
However Dgyver - that sissy bar you can leave out ... so your welding can be eliminated. If you want to put that sissy bar, you're gonna have to weld. Anything else will leave you a sissy bar bracket that is clamped on to thin ass sheet metal and thin wall tubing. Its OK to carry body work, not to have you grap that bar and have it come off in your hand. Yea for how thin the tail section is your welding it is going to really hurt ... yea right.
Cool.
Srinath.

[dgyver]

From what I remember the grab handle mount are the same. I would need to compair the sub-frames again, it has been awhile.

Who said anything about clamping and thin sheet metal? Not me.