I have a '98 Kawasaki Bayou 300 2wd. I am working on it for my graduation project for school. I will be removing the front rack and bumper, making a new bumper, replacing the 2 headlights with 1 bigger lamp, and cutting the front fenders to make it look more sporty. The rear racks will not change to much. I will also be re-gearing the tranny, and may get a new pipe for it. As of right now it is completly stock except for the tries.

I have the repair manual for it, therefore I know how to change the gearing. I also have an uncle that knows about welding and metal fab. The only part of this project I do not know how to do is cutting the plastics. Any help is deffinatlly appricated. If you have any suggections on something else to do don't hesitate to reply. Thankyou

 

Jigsaw w/soft wood blade.

 

I've had to cut some plastic on my 650 and I used a Dremel tool with a cutting blade. You can be pretty accurate and it will allow you to cut round corners, etc. It will also let you clean up any edges left behind from the cut. I had to make a cut on the handle bar plastic for a GPS mount and also cut the bottom of the mud flaps off (the were always catching on something!!!). The high/variable speed of the tool allows you to get a nicely finished cut.

 

Use a air or electric dremal it doesn't matter, air is more contralable because it's infinate number of speeds (Gear shift vs Hydrostatic) use some type of measuring devise to make it some what accurate, once it's cut off you can't put it back on.

1. Think about it and find the look you like TAKE YOUR TIME

2. Mark out the design with a dry-erase marker

3. Carefully with a carbide bit in a Dremal start cutting, cut with the Dremal motor facing the underside of the plastic.

4. When you've got the most of the material taken off get a piece of wood ( 6" piece of 1x4) and stapel some 220 grit sandpaper to it. This will help prevent wavy edges.

5. Hit it once without the block with 320 grit and last 400 Grit.

My website kinda explains how I did myn

 

I used a Hacksaw blade and cut my fenders by and then took the bike to work and used a rotorary sander to make it smooth...I was very pleased with the results!