Mako, it's quite an awkward design or I'm not sequencing it properly. From what I experienced you can't remove the front wheel or the front fender without removing at least one caliper because of the way the brake line fits in the rise molded in the fender. I put the bike on the center stand (naturally) and then jacked up the front of the motor as high as I could get it till the rear wheel touches the ground - that allows the front wheel to drop straight down giving max clearance to work with the calipers and fender but still be 'inside' the calipers when they're mounted on the forks. I removed the left caliper and moved it down and forward enough to wrangle the fender out. I remounted the caliper and formed the brake line as symmetrical as I could. Then I removed the left caliper again and gently moved it until I could fish the fender back in place and remounted the caliper - you know the rest from there. Being aware of the problem let me tweak the brake line a little more after the fender was bolted in place.
ps. I forgot to mention that this is all accomplished by sliding the fork caps up and removing the fork brace.
Sorry about the long explanation for such a silly problem - Rod
Twisted front fender r100rt
Re: Twisted front fender r100rt
Good job Rod. I'll tackle mine soon. Thanks and cheers.