Like Pleiades said, there is no danger damaging fuel tank, because the levers are lower than the tank. I have hit the bike on the side many many times, and I never hit it with an angle or object, that would indager damaging fuel tank with the levers behind the panels.

You can see on the picture below the red line is seen the line where the tank sits ( the line is made by manny hits on the ground) Red arrow shows the side, where the tank is closely to the panel, below that line, there is room for a fist.

So the lever is safely below that line.

But I would advise on the right side panel, to put the lever a bit more to the back side, so the lever is not too close to the radiator and radiator pipe.
I did thought about it, and that was the only possible danger I noticed.
Again, I hope I am right.

http://shrani.si/f/42/x/47azykf1/side-plastic.jpg

Thanks for that. Nice and clear. Might lookat using that space as well.

Cheers

Really nice work. :clap:

Just to let you all know....
Tape under the side plates did hold our last 14 day sahara adventure, and spare levers did not fall of them. But I will make closer inspection soon, to check it if its right on place as I left them.
You can check the trip here:
http://advrider.com/forums/showthread.php?t=770676

Bash plate
 

Some of you PM-ed me for blueprints of the bash plate, so also sticking it here, if anyone interested to build one on his own.

Here you have simple template to start with.
Other stuff you will neeed to improvise as I did.


http://shrani.si/f/23/qG/2bmQApny/1/...bash-plate.jpg http://www.shrani.si/f/2r/w2/3LgyHzf4/img3618.jpg

This is one of my last upgrades...

Since original Tenere rear rim is 17", its not the best size for offroading in many ways. I decided to put 18" rear wheel on my Tenere.
That way I have more tire options for off roading, better ground clearance, better traction, rim lock for lower air pressure...

Since new Excel rims are expensive, I searched ebay for any used DID or Excel 18" rim, that is 2,5 wide and with 36 spike holes. You can get such used rim from Yamaha XT 600, YZ490...

I sand blasted it, gave it a powdercoat...
Bought new thicker longer 18" spokes from OTR and put it together.
http://shrani.si/f/3g/iz/3hXJjFhV/img20131123171120.jpg

Spoke assembling finished and centered
http://shrani.si/f/2j/Am/4QoWSXtG/cy...1125184613.jpg



Tire and rim lock is on, also heavy duty 4-5mm Continental tube
http://shrani.si/f/n/hX/1y5fxcWt/cym...1125210936.jpg


Meanwhile also rear shock service was made
http://shrani.si/f/E/s2/34PtjCBn/cym...1126183425.jpg


Also had to change the sprockets, to keep the gear ratio.
Since rear wheel is now bigger (you can put 1 tooth smaller sprocket in front, or 3 tooth bigger sprocket in the rear, too keep approximately the same gear ratio)
http://shrani.si/f/1k/LZ/2icfqCMq/cy...1125212940.jpg


Rear end is now completely serviced and ready for new adventures.
I gave it a first test ride - off road, and it feels as expected.
It seems to be great.

http://shrani.si/f/2y/1h/4AJFGhJr/cy...10164120-1.jpg

Suspension conversion YZ250F part 1.
 

Hello,
here are some latest upgrades...
So I made some pics,and put additional information.
If someone would like to do this conversion, it might help him.

I bought Yamaha YZ250F 2004 complete front end.
With this conversion you get:
-from 230 mm (original) to 300 mm suspension travel.
-stronger suspension, since YZ has 48 mm telescope diameter (original 42mm)
-fully adjustable suspension (rebound and compression)
-you loose astonishing 8,6 kg of weight, since YZ suspension is lighter, better materials, more aluminium used instead of regular steel!

Removed original front end
http://shrani.si/f/w/VW/3SBrpLOT/img3664.jpg

http://shrani.si/f/2I/Xn/4P91gEJJ/img3676.jpg



Upper triple clamp is lower for 3 cm, so if you use 3 cm handlebar risers, you will be back to original height.
http://shrani.si/f/3i/cH/1kAVCmHM/img3679.jpg



I used axle from the left, lower triple clamp (in the middle, from YZ), and triple clamp from the right (upper triple clamp from YZ)
http://shrani.si/f/3X/R5/41eF6ncF/img3687.jpg



To make it happen, you need hydraulic press, to remove axle from original triple clamp, and fit it to YZ triple clamp.
http://shrani.si/f/1O/Zl/1OyynLDX/img20140531081948.jpg



Upper triple clamp from YZ has slightly bigger axle hole, so you need to make bushing to make a tight fit.
http://shrani.si/f/1I/ih/1Ywqko47/img20140531083914.jpg



Set needed to fit to Yamaha Tenere is ready.
Now we have here lower triple clamp from YZ, axle from Tenere, and upper triple clamp from YZ with fabricated bushing to make a proper fit.
http://shrani.si/f/i/53/1xckxdnQ/img3689.jpg



From here on, its an easy job.
Assembling:
http://shrani.si/f/20/t3/3ChinMVQ/img3692.jpg

http://shrani.si/f/1v/12c/2KyimBWb/img3697.jpg

http://shrani.si/f/1O/10q/1xRQIY94/img3694.jpg



Fitted:
http://shrani.si/f/23/mQ/1G25YheE/img20140531114259.jpg


But conversion is not finished here.
-To make bike really better, I still have to put oversize front brake disc and adapter for caliper, to improve braking as close as possible to original.
-I have to put on stiffer springs (original YZ 3Nm) to 5Nm or 5,2Nm. Since bike is much heavier than YZ.
-I have to make steering lock, so the triple clamp will not touch radiator.

I will update these info also when I solve them.

Tenere suspension upgrade part two
 

Thank you very much Pepsi.

Today my new springs arrived!

So, since Tenere is much heavier than YZ, I had to find stiffer springs.
I managed to find a specialist SLAVENS RACING, that was able to manufacture a special spring for my bikes characteristics. So he made for my setting 5,8 N/mm spring rate.
While changing the springs, I also made a complete servise of the forks...

Disasembling lower end
http://shrani.si/f/46/DQ/4NR7eEEB/img45171.jpg

Oil draining
http://shrani.si/f/K/vw/3M41h3zQ/img45201.jpg

disasembling upeer end
http://shrani.si/f/13/TA/oNPdtsw/img45251.jpg


Spring removal
http://shrani.si/f/3g/WX/4JYzYsuC/img45271.jpg

http://shrani.si/f/2F/22/3yCFT7Cu/img45341.jpg

http://shrani.si/f/d/G/Drb3emr/img45361.jpg



Removing dust cap and lock spring
http://shrani.si/f/2O/Z9/2Qe96S9m/img45291.jpg



Removing dust cap, spring, oil seal, inner bushing, outer bushing
http://shrani.si/f/2u/8x/44uZu38b/img45461.jpg


Putting on new parts
http://shrani.si/f/o/Pc/1l3Fhnwe/img45501.jpg


New spring is 10 mm longer and material is thicker
http://shrani.si/f/U/vc/178FEjjK/img45571.jpg


Assembling in back order...
http://shrani.si/f/u/Uv/2sgOrT4F/img45591.jpg


And test ride:
http://shrani.si/f/h/f1/1pXIf53G/img45631.jpg

Bike handles extremely well. Now literally eats, step roots, holes, rock,... you name it... Complete COMPRESSION/REBOUND setting and 30 cm of travel makes a huge difference.


I should get oversize front brake disc and andapter this week, and put it on.
Than the conversion is done.

I want to everything you have done but alas my skills are zero.

Now if somebody sold a kit to make 2nd forks fit the tenere I bet they would sell well.

Mike

Congratullations!! very nice work.
I wish to have your mechanic skills!! BRAVO!