DIY Beta 390 RR-S Rear Fender Repair: The Zip Tie Stitch Method

Updated at: 16/02/2025

The Husqvarna Beta 390 RR-S is a powerful and agile machine, but its rear fender, unfortunately, isn't known for its robust durability. Rips and tears are a common occurrence, often leaving riders stranded or facing costly repairs. This is particularly frustrating given the bike's otherwise impressive performance. Traditional methods of repair can be time-consuming, expensive, or require specialized tools many riders don't possess. Thankfully, there's a surprisingly effective and accessible solution that requires minimal materials and skill.

This article outlines a simple, yet remarkably sturdy, method for repairing a damaged Beta 390 RR-S rear fender using nothing more than zip ties. Forget about expensive welding or complicated fiberglass work; we'll guide you through a step-by-step process utilizing the "zip tie stitch" technique, allowing you to get back on the trail quickly and economically. Let's dive into the repair process and get your fender back in fighting shape.

Preparation and Safety Guidelines

Tools Needed
  • 8mm Allen keys
  • Screwdrivers
  • Zip ties
  • Sharpie
  • Drill
  • Vice grips
  • Adjustable wrench
  • Hammer
Safety Guidelines
  • Always wear appropriate safety gear, including eye protection and gloves, when working with sharp objects and plastics.
  • Ensure the motorcycle is stable and securely supported on a jack stand before beginning any repairs. Never work under a motorcycle supported only by its kickstand.
  • Use high-quality zip ties rated for appropriate tensile strength. Inferior zip ties may fail under stress, potentially leading to further damage or injury.

Step-by-Step Instructions

  1. Fender Removal

    • Remove the eight millimeter bolts securing the rear fender.
    • Remove two Allen keys on top of the fender.
    • Remove the inner fender piece (license plate holder) secured by four 8mm self-tapping screws.
    • Disconnect the fender from the bottom of the bike by removing an 8mm bolt in the center.
    Disconnect the fender from the bottom of the bike by removing an 8mm bolt in the center.Disconnect the fender from the bottom of the bike by removing an 8mm bolt in the center.Disconnect the fender from the bottom of the bike by removing an 8mm bolt in the center.Disconnect the fender from the bottom of the bike by removing an 8mm bolt in the center.
    Fender Removal
    • Remove two more 8mm self-tapping screws from the sides of the fender.
    • Remove the fender completely.
    Remove the fender completely.Remove the fender completely.
    Fender Removal

  2. Bracket Repair

    • Straighten the bent support bracket underneath the fender using vice grips, an adjustable wrench, and a hammer.
    Straighten the bent support bracket underneath the fender using vice grips, an adjustable wrench, and a hammer.
    Bracket Repair

  3. Fender Preparation

    • Clean the broken area of the fender.
    • Mark stitch locations on the broken fender using a Sharpie.
    • Drill small holes at the end of the cracks to prevent further cracking.
    Drill small holes at the end of the cracks to prevent further cracking.Drill small holes at the end of the cracks to prevent further cracking.Drill small holes at the end of the cracks to prevent further cracking.
    Fender Preparation

  4. Zip Tie Repair

    • Stitch the broken parts together using small zip ties.
    Stitch the broken parts together using small zip ties.
    Zip Tie Repair

  5. Fender Reattachment

    • one screw might be missing.
    • Remount all other components (lights, etc.)
    Remount all other components (lights, etc.)Remount all other components (lights, etc.)
    Fender Reattachment

Read more: DIY Motorcycle Mudguard Restoration: A Step-by-Step Guide

Tips

  • Using a sock over your air filter can extend its life.
  • Take detailed notes during the repair process.
  • Drill holes at the end of cracks to prevent spreading.

Common Mistakes to Avoid

1. Using Zip Ties That Are Too Short

Reason: Short zip ties won't provide enough coverage or tension, leading to a weak and ineffective repair.
Solution: Use longer zip ties to ensure adequate overlap and secure fastening.

2. Incorrect Zip Tie Placement/Tension

Reason: Uneven tension or placement can cause the fender to bulge or become misaligned, resulting in an unsightly and potentially unsafe repair.
Solution: Distribute zip ties evenly and apply consistent tension to maintain fender shape and stability.

3. Ignoring Underlying Fender Damage

Reason: Trying to zip-tie a severely cracked or broken fender without addressing the main damage will result in a temporary and unreliable fix.
Solution: Reinforce or repair significant cracks or breaks before using zip ties for added support.

FAQs

Will this zip tie repair method affect my bike's performance?
No, this is a purely cosmetic repair. The zip tie method only addresses the broken fender; it doesn't impact the bike's mechanical function or handling.
How long will this zip tie repair last?
It depends on the riding conditions and the strength of the zip ties used. Expect a temporary fix lasting a few rides to a couple of weeks. It's not a permanent solution and will likely need replacing eventually.