Puig Rear Fender Extension 3677J Installation Manual

1. Introduction

This manual provides detailed instructions for the proper installation and maintenance of the Puig Rear Fender Extension, model 3677J. This accessory is designed to offer additional protection to your motorcycle's rear section, specifically compatible with Kawasaki Versys 1000 models from 2019 to 2020.

The fender extension is manufactured from high-resistance ABS material and finished in matte black to seamlessly integrate with your vehicle's aesthetic.

2. Safety Information

• Always ensure the motorcycle is stable and securely supported before beginning any installation.
• Wear appropriate personal protective equipment, including safety glasses and gloves.
• If you are unsure about any step, consult a qualified motorcycle mechanic.
• Keep all tools and small parts away from children.
• Ensure the motorcycle's engine is off and cool before starting work.

3. Package Contents

Verify that all components are present before starting the installation:

• 1x Puig Rear Fender Extension (Model 3677J)
• Mounting hardware (screws, washers, nuts as required)

Note: Specific tools required for installation (e.g., drill, drill bits, wrenches) are not included and must be supplied by the user.

Figure 3.1: The Puig Rear Fender Extension component.

4. Setup and Installation

The installation of the Puig Rear Fender Extension requires drilling holes into the motorcycle's original rear fender. Proceed with caution.

1. Prepare the Motorcycle: Park the motorcycle on a level surface and secure it on its center stand or a paddock stand. Ensure the rear wheel is accessible and stable.
2. Clean the Installation Area: Thoroughly clean the surface of the original rear fender where the extension will be mounted. This ensures proper adhesion and marking.
3. Position the Extension: Carefully place the Puig Rear Fender Extension against the original fender to determine its exact mounting position. Ensure it aligns correctly with the contours of the existing fender.
4. Mark Drilling Points: Using a marker or pencil, accurately mark the drilling points on the original fender through the pre-drilled holes on the Puig extension. Double-check the alignment before marking.


Figure 4.1: Illustrative diagram of the fender extension's position relative to the rear wheel.

5. Drill Holes: Using an appropriate drill bit size (refer to the provided hardware for exact dimensions), carefully drill holes at the marked points on the original fender. Start with a small pilot hole if necessary, and ensure not to damage any underlying components.
6. Attach the Extension: Align the Puig Rear Fender Extension with the newly drilled holes. Secure the extension to the original fender using the provided screws, washers, and nuts. Tighten all fasteners firmly but do not overtighten to avoid stripping threads or cracking the material.


Figure 4.2: Close-up view of the Puig Rear Fender Extension installed on a motorcycle.



Figure 4.3: Side view of the installed fender extension.

7. Final Check: After installation, visually inspect all connections to ensure they are secure. Gently test the stability of the fender extension.

5. Operating

The Puig Rear Fender Extension is a passive component designed to provide additional protection from road debris and water spray. No specific operational steps are required after installation. However, it is recommended to periodically check the mounting screws for tightness, especially after riding on rough terrain or after washing the motorcycle.

6. Maintenance

• Cleaning: Clean the fender extension with mild soap and water. Avoid using harsh chemicals or abrasive cleaners that could damage the matte finish or the ABS material.
• Inspection: Regularly inspect the fender extension for any signs of damage, cracks, or loose mounting hardware. Address any issues promptly to ensure continued protection and safety.

7. Troubleshooting

• Loose Fit: If the fender extension feels loose after installation, re-check all mounting screws and ensure they are tightened correctly. Do not overtighten.
• Misalignment: If the extension does not align properly, carefully review the marking and drilling steps. Ensure the original fender is not warped or damaged.
• Damaged Part: If the fender extension or any mounting hardware is damaged upon receipt or during installation, do not proceed with installation. Contact Puig customer support for assistance.

8. Specifications

9. Warranty and Support

For information regarding product warranty, please refer to the official Puig website or contact your authorized Puig dealer. For technical support or further assistance with installation, please visit the Puig official website or contact their customer service department.