Drilling rear fender on KTM 690 Enduro - installation of handrails or racks

New KTM 690 Enduro's are delivered without holes on the rear plastic fender. In order to mount handrails, luggage rack or pannier rack, some drilling is required. No special tools are needed, just standard tools, drill and 15 or 16 mm wood drill bit. 

This is how rear fender of new bike looks. 

First, we need to remove rear fender. Remove the seat and fuel cap. Unplug little hose. 

Next, unbolt all bolts holding plastic fender. 

Now fender should be easily removed. 

Place it on solid surface and check for markings on the inside. Markings will look like on the photo bellow. 

For better visibility, mark them with strong marker or something similar.

Each hole has little punch mark in the middle, so drilling should be easy. Use standard brad point wood drill bit - LINK or self cut spade bit - LINK or core cutter with pilot drill like. Radius of the drill bit should be 15 or 16 mm. I prefer 16 mm. Take it easy with drilling speed. Make sure to align the drill well. 

After few moments, fender should look like this.

Take few moments with knife, file or deburring tool and remove excess material of the edges. 

Mount the fender and make sure all bolts are in their place. Three bolts under the tail should be carefully bolted - do not over tighten them. If they are aligned well, you will feel when you should stop. Push the hose back into fuel cap base. 

Make sure everything fits fine and place the seat. 

Your shiny new KTM is ready to be equipped with handrails, luggage rack or pannier rack. If you haven't made your mind yet, check Perun moto KTM 690 Enduro Luggage rack SD.

IMPORTANT: whatever you mount, do not use thread locker for these 4 holes. Threaded inserts molded in the plastic tank need to be treated with care. Also, make sure not to over tighten bolts - 15 Nm is fine.