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Tutorial Fitting Suzi Dl650 Hanguards To The Tdm 900

Started by Hartside Man , Jan 23 2007 07:55 pm

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#21 BigC

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Posted 19 February 2007 - 12:57 pm

QUOTE(Hartside Man @ Sun 18th Feb 2007, 03:43 PM) <{POST_SNAPBACK}>
the only problem using a threaded bar is the fact the lever has a soft bush in it and will wear prematurely on the peaks of the thread unsure.gif

if i was you i would bite the bullet and drill the thread out. this will not cause you any issue if you want to go back to standard as the standard yam bolt has a locknut on the bottom anyhow good.gif

however if the bush wears (with the thread) then there is a possibility it could ride on the thread like a nut and lock up on the top or the bottom of the lever mount huh.gif

just my thoughts as an engineer yeahyeahyeah.gif



arse.

looks like the bullet will have to be bit.

do you reckon a handrill will be ok as i dont have access to a powerdrill.

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#22 Hartside Man

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Posted 19 February 2007 - 04:50 pm

QUOTE(BigC @ Mon 19th Feb 2007, 12:42 PM) <{POST_SNAPBACK}>
arse.

looks like the bullet will have to be bit.

do you reckon a handrill will be ok as i dont have access to a powerdrill.


not a problem a handrill will more than suffice, in fact if you had a good grip you could possibly twist the drill through with your fingers rolleyes.gif

i removed the mirror to make the job a bit easier banana.gif

6mm drill is all thats required dont go larger or the shouldered new bolt will slip through and dont overtighten, as your using locknuts there is no need to crank it too tight, just enough to grip the plastic cool.gif

>>>>>>>>>>>>>>>>>>>>>>>>>>>>>

I have a Ghost S and i'm not afraid to use it !

A Beast in Orange Called KaTie eM 

"Four wheels move the body. Two wheels move the soul".

"So you just ride somewhere, eat cake and then ride back".

"Normal people believe that if it ain't broken, don't fix it. Engineers believe that if it ain't broken, it doesn't have enough features yet."

 

" I We're Ridin so Fast , I we're sucking Rabbits from the Hedges "   {Guy Martin}

#23 BigC

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Posted 20 February 2007 - 06:08 pm

all done, thanks for your help cool.gif

just waiting on the bar ends now

Edited by BigC, 20 February 2007 - 06:09 pm.


Twin Carbon Can Co Exhausts, TomTom Rider, Scotoiler, Wingrack 2 with 2xGivi E360 panniers, Monokey Plate / Monolock Plate, E360 topbox / E450 topbox, Fenda Extenda, MRA Vario Touring Screen, Stainless Steel Rad Cover, Top Saddlery Tank Cover, Suzuki DL650 Handguards, Pressure Alert Valve caps

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"Most of the gear, absolutely no idea!"

#24 Bomber

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Posted 21 February 2007 - 08:18 am

Fitted the handguards last night after getting bar ends machined by a local company. Took me about 45 minutes but in my defence I'm not the most technically gifted and there was a fair bit of umming and ahhhing going on.
The excellent tutorial from Hartside Man helped immensely and I have to say that I think the guards look pretty damn good on the bike, almost as if they were stock Yamaha items !

Thanks guys.
Bomber

#25 Hartside Man

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Posted 23 February 2007 - 01:02 am

QUOTE(Bomber @ Wed 21st Feb 2007, 08:03 AM) <{POST_SNAPBACK}>
Fitted the handguards last night after getting bar ends machined by a local company. Took me about 45 minutes but in my defence I'm not the most technically gifted and there was a fair bit of umming and ahhhing going on.
The excellent tutorial from Hartside Man helped immensely and I have to say that I think the guards look pretty damn good on the bike, almost as if they were stock Yamaha items !

Thanks guys.


Glad i could be of help to you guys, and yes i think they look good on the 900 as well good.gif

>>>>>>>>>>>>>>>>>>>>>>>>>>>>>

I have a Ghost S and i'm not afraid to use it !

A Beast in Orange Called KaTie eM 

"Four wheels move the body. Two wheels move the soul".

"So you just ride somewhere, eat cake and then ride back".

"Normal people believe that if it ain't broken, don't fix it. Engineers believe that if it ain't broken, it doesn't have enough features yet."

 

" I We're Ridin so Fast , I we're sucking Rabbits from the Hedges "   {Guy Martin}

#26 Hartside Man

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Posted 24 February 2007 - 03:31 am

QUOTE(Bomber @ Wed 21st Feb 2007, 08:03 AM) <{POST_SNAPBACK}>
Fitted the handguards last night after getting bar ends machined by a local company. Took me about 45 minutes but in my defence I'm not the most technically gifted and there was a fair bit of umming and ahhhing going on.
The excellent tutorial from Hartside Man helped immensely and I have to say that I think the guards look pretty damn good on the bike, almost as if they were stock Yamaha items !

Thanks guys.


so did everything click into place ? like were the barends machined at the correct point for you ? and have you got standard bars fitted ?

all feedback welcome cool.gif

>>>>>>>>>>>>>>>>>>>>>>>>>>>>>

I have a Ghost S and i'm not afraid to use it !

A Beast in Orange Called KaTie eM 

"Four wheels move the body. Two wheels move the soul".

"So you just ride somewhere, eat cake and then ride back".

"Normal people believe that if it ain't broken, don't fix it. Engineers believe that if it ain't broken, it doesn't have enough features yet."

 

" I We're Ridin so Fast , I we're sucking Rabbits from the Hedges "   {Guy Martin}

#27 Bomber

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Posted 24 February 2007 - 08:45 am

Yes

Yes

& Yes

Little bit of fettling to the handguards with a junior hacksaw blade as I couldn't be asked/didn't want to change the angle of the brake and clutch levers or move the throttle.
Bomber

#28 BigC

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Posted 01 March 2007 - 03:42 pm

QUOTE(Hartside Man @ Sat 24th Feb 2007, 03:16 AM) <{POST_SNAPBACK}>
so did everything click into place ? like were the barends machined at the correct point for you ? and have you got standard bars fitted ?


finally picked up bar ends at the weekend and no problems at all with everything fitting together, its a tight fit to get the handguard clips in the bar ends but apply a bit of pressure and it just pops in, also i suppose you need that tight fit to stop them popping out.

oh and have standard bars fitted.

Twin Carbon Can Co Exhausts, TomTom Rider, Scotoiler, Wingrack 2 with 2xGivi E360 panniers, Monokey Plate / Monolock Plate, E360 topbox / E450 topbox, Fenda Extenda, MRA Vario Touring Screen, Stainless Steel Rad Cover, Top Saddlery Tank Cover, Suzuki DL650 Handguards, Pressure Alert Valve caps

Unused - Blue Tall Screen
"Most of the gear, absolutely no idea!"

#29 phoneman

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Posted 03 March 2007 - 11:32 pm

Just wanted to add my thanks to Hartside Man. The modded bar ends came back yesterday so the fit was finished this morning. The guards fitted to the bar ends with a nice solid clunk. They look like they were made for the bike.
Phoneman (Mike)

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#30 Hartside Man

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Posted 04 March 2007 - 09:40 pm

QUOTE(phoneman @ Sat 3rd Mar 2007, 11:17 PM) <{POST_SNAPBACK}>
Just wanted to add my thanks to Hartside Man. The modded bar ends came back yesterday so the fit was finished this morning. The guards fitted to the bar ends with a nice solid clunk. They look like they were made for the bike.



It's Nice to see it's all working out well chaps good.gif

>>>>>>>>>>>>>>>>>>>>>>>>>>>>>

I have a Ghost S and i'm not afraid to use it !

A Beast in Orange Called KaTie eM 

"Four wheels move the body. Two wheels move the soul".

"So you just ride somewhere, eat cake and then ride back".

"Normal people believe that if it ain't broken, don't fix it. Engineers believe that if it ain't broken, it doesn't have enough features yet."

 

" I We're Ridin so Fast , I we're sucking Rabbits from the Hedges "   {Guy Martin}

#31 TDMTAM

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Posted 10 March 2007 - 08:55 pm

QUOTE(amarko5 @ Tue 23rd Jan 2007, 07:40 PM) <{POST_SNAPBACK}>
Right then, first you need to buy the Suzuki DL650 VStrom Handguard kit (usually 22 UKP from a dealer)
Jobs a Carrot banana.gif Cheap and easy alternative to the BMW ones. good.gif


Do you have the part No. for the handguard kit?
TAM
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1994 TDM 850 mkI Silver, with Blueflame end can, Gone to a new owner & I kinda miss her!

th_09062006104.jpg th_02012009095.jpg

Only a Biker knows why a Dog sticks it head out the car window

#32 Hartside Man

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Posted 10 March 2007 - 10:45 pm

QUOTE(TDMTAM @ Sat 10th Mar 2007, 08:40 PM) <{POST_SNAPBACK}>
Do you have the part No. for the handguard kit?
TAM


Tam if you go to any suzuki dealer and ask for the DL650 handguard kit (its an optional extra in their catalogues) don't know the number of the kit but its the only one suzuki do for the 650 DL .

>>>>>>>>>>>>>>>>>>>>>>>>>>>>>

I have a Ghost S and i'm not afraid to use it !

A Beast in Orange Called KaTie eM 

"Four wheels move the body. Two wheels move the soul".

"So you just ride somewhere, eat cake and then ride back".

"Normal people believe that if it ain't broken, don't fix it. Engineers believe that if it ain't broken, it doesn't have enough features yet."

 

" I We're Ridin so Fast , I we're sucking Rabbits from the Hedges "   {Guy Martin}

#33 TDMTAM

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Posted 11 March 2007 - 07:28 am

QUOTE(Hartside Man @ Sat 10th Mar 2007, 10:30 PM) <{POST_SNAPBACK}>
Tam if you go to any suzuki dealer and ask for the DL650 handguard kit (its an optional extra in their catalogues) don't know the number of the kit but its the only one suzuki do for the 650 DL .


Thats the problem I Refuse to go in to my local Suzuki dealer ( Mickey (Mouse)Oats) ranting.gif I was hopeing to get the number so I could order it through Robison suzuki who I used to order my spare for the Bandit.
TAM

Just been on to the suzukiGB site & have found the part no. is Hand guard set 57300-27820-291
Now I just need to order myself a set.
TAM

Edited by TDMTAM, 11 March 2007 - 07:38 am.

2008 TDM 900 in BLACK, MRA Vario, DL handguards & more to come
1994 TDM 850 mkI Silver, with Blueflame end can, Gone to a new owner & I kinda miss her!

th_09062006104.jpg th_02012009095.jpg

Only a Biker knows why a Dog sticks it head out the car window

#34 TDMTAM

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Posted 31 March 2007 - 08:50 am

QUOTE(TDMTAM @ Sun 11th Mar 2007, 08:13 AM) <{POST_SNAPBACK}>
Just been on to the suzukiGB site & have found the part no. is Hand guard set 57300-27820-291
Now I just need to order myself a set.
TAM


Well finally ordered as set & they arrived today, so tonight I will mostly be in the garage fitting them to the TDM. will try to remember to take pictures.
I will also be getting the wee RD250 ready for its MOT banana.gif
TAM
2008 TDM 900 in BLACK, MRA Vario, DL handguards & more to come
1994 TDM 850 mkI Silver, with Blueflame end can, Gone to a new owner & I kinda miss her!

th_09062006104.jpg th_02012009095.jpg

Only a Biker knows why a Dog sticks it head out the car window

#35 dbninja

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Posted 31 March 2007 - 07:16 pm

Excellent tutorial good.gif

ordered a set of dl650 handguards today ... £24 from ESB Bolton


bikes coming on a treat... heated grips, centre stand, Givi top-box and plate. Scottoiller fitted today. handguards ordered, pannier rails on their way.... its like Christmas! yahoo.gif


thanks for the info

dbn
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#36 TDMTAM

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Posted 31 March 2007 - 10:10 pm

QUOTE(TDMTAM @ Sat 31st Mar 2007, 09:35 AM) <{POST_SNAPBACK}>
Well finally ordered as set & they arrived today, so tonight I will mostly be in the garage fitting them to the TDM. will try to remember to take pictures.
I will also be getting the wee RD250 ready for its MOT banana.gif
TAM





Well finally got them on, There is a few differences with fitting them to a mkI TDM. Clutch side is much the same, it is the throttle side that differs. The brake pivot bolt has the be changed and the hole at the top of the brake master cylinder assembly need drilled out to 8.0mm, & the steel insert in the brake lever has to be bored out to 8.0mm to. This is hard bit as the insert is only 9.5mm.
Also becuase I have Rental Medium road bar with renthal bar weights, the bar weights have to have the step on them removed.
hope this is of help to others.
TAM

some more pictures hopefully!!!

Edited by TDMTAM, 02 April 2007 - 04:41 pm.

2008 TDM 900 in BLACK, MRA Vario, DL handguards & more to come
1994 TDM 850 mkI Silver, with Blueflame end can, Gone to a new owner & I kinda miss her!

th_09062006104.jpg th_02012009095.jpg

Only a Biker knows why a Dog sticks it head out the car window

#37 Hartside Man

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Posted 01 April 2007 - 09:39 pm

QUOTE(TDMTAM @ Sat 31st Mar 2007, 09:55 PM) <{POST_SNAPBACK}>

Well finally got them on, There is a few differences with fitting them to a mkI TDM. Clutch side is much the same it is the throttle side. The brake pivot bolt has the be changed and the hole at the top of the brake master cylinder assembly need drilled out to 8.0mm, & the stell insert in the brake leverhas to be bored out to 8.0mm to. This is hard bit as the insert is only 9.5mm.
Also becuase I have Rental Medium road bar with renthal bar weights, the bar weights have to have the step on them removed.
hope this is of help to others.
TAM

some more pictures hopefully!!!


excellent Tam good.gif so now we have several fitment methods for several types of bars and models of bikes. this is the type of thread i like yahoo.gif

>>>>>>>>>>>>>>>>>>>>>>>>>>>>>

I have a Ghost S and i'm not afraid to use it !

A Beast in Orange Called KaTie eM 

"Four wheels move the body. Two wheels move the soul".

"So you just ride somewhere, eat cake and then ride back".

"Normal people believe that if it ain't broken, don't fix it. Engineers believe that if it ain't broken, it doesn't have enough features yet."

 

" I We're Ridin so Fast , I we're sucking Rabbits from the Hedges "   {Guy Martin}

#38 TDMTAM

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Posted 02 April 2007 - 04:43 pm

QUOTE(Hartside Man @ Sun 1st Apr 2007, 10:24 PM) <{POST_SNAPBACK}>
excellent Tam good.gif so now we have several fitment methods for several types of bars and models of bikes. this is the type of thread i like yahoo.gif

Glad to be of help
TAM
2008 TDM 900 in BLACK, MRA Vario, DL handguards & more to come
1994 TDM 850 mkI Silver, with Blueflame end can, Gone to a new owner & I kinda miss her!

th_09062006104.jpg th_02012009095.jpg

Only a Biker knows why a Dog sticks it head out the car window

#39 Mikey B

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Posted 17 June 2007 - 07:11 pm

Excellent tutorial. Easy & straight forward to follow.
Very imformative. Once the bar end were machined, the guards were fitted in approx 45 mins.

Picked my guards up from JT motorcycles in Cwmbwrla (Swansea) on Thursday - £24.50, fitted them today (Sun). They did tell me that they are selling a lot of these guards for bikes not necessary the VStrom. They asked where I got the info from and pointed them in this direction.

Look the dogs danglies on the bike.

Cheers & thanks to Hartside man. drinks.gif

Edited by Mikey B, 17 June 2007 - 07:14 pm.

#40 Pilot Paul

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Posted 17 August 2007 - 11:26 am

Got a mate at work to do the bar ends and have now fitted my DL650 hand guards - looks a very professional job using this technique. Ta for the info.

Paul
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