Bloody good mod. I've done it to my bike and they look great
Tutorial Fitting Suzi Dl650 Hanguards To The Tdm 900
Started by
Hartside Man
, Jan 23 2007 07:55 pm
92 replies to this topic
#61
Pastitoo
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sticking around
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Posted 22 February 2008 - 07:56 am
#62
Baron
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Posted 22 February 2008 - 11:03 am
I was looking to fit the BMW R1150GS handguards to my new 9'er as I had to my last one but looking at these Suzuki ones I've changed my mind. I think the Suzuki ones, apart from costing less look like they will provide better wind protection for the back of my hands as they look to be a little higher than the BMW ones. I just need to sort out a machine shop in the Aberdeen area to do the bar end weights.
In reducing the bar end weights, err, weight by machining them does it change their vibration dampening characteristics at all?
In reducing the bar end weights, err, weight by machining them does it change their vibration dampening characteristics at all?
Gone but not forgotten: 2007 TDM900ABS Competition White, datatagged, fenda extenda, tomtom rider 1, Yamaha main stand, Yamaha heated grips, HID headlights, Yamaha top box & city side cases, MRA Vario screen, CLS200 automatic chain oiler, Yamaha belly pan, DL650 handguards, Gi-Pro X gear indicator, SW-Motech Mirror Extensions, LED side light, Stebel Nautilus AIR HORN!!!!!
(1974....KTM Comet Cross, RD250B, XS750, Wife & kids, DT175, Suzuki GT500, XT500, XT500 (modified), ZX-10 (the 1st one!), Yamaha TT600R, Suzuki GT750B, GT750K, '04 TDM900, GSX1100F, '07 TDM900A, '06 FJR1300A
(1974....KTM Comet Cross, RD250B, XS750, Wife & kids, DT175, Suzuki GT500, XT500, XT500 (modified), ZX-10 (the 1st one!), Yamaha TT600R, Suzuki GT750B, GT750K, '04 TDM900, GSX1100F, '07 TDM900A, '06 FJR1300A
#63
Matlock
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Posted 22 February 2008 - 12:14 pm
QUOTE(Baron @ Fri 22nd Feb 2008, 10:48 AM) <{POST_SNAPBACK}>
In reducing the bar end weights, err, weight by machining them does it change their vibration dampening characteristics at all?
Not that I noticed. It's probably less than 10% of the bar end that gets removed when the slot is machined.
2002 TDM900 in glorious yellow, NOW SOLD 
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#64
Daveb
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Posted 22 February 2008 - 05:47 pm
Fitted the DL65 handguards last weekend to MKII 850, Hartside mans tutorial excellent, same as AJFergie had to drill out RHS thread and brake level insert, cut a little from under side of guard for brake resivour. No need to machine bar ends as I used the polysport bar weights from the polysport handguards which I fitted a few years ago along with Renthal bars.
2007 Triumph Tiger 955i
#65
Pepy27
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seems to like Carpe
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Posted 08 April 2008 - 11:58 am
Top instructions......even a mechanically challenged berk like me can fit them! 
Done by the way!
Done by the way!
#66
Studley Ramrod
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Posted 08 April 2008 - 06:29 pm
I managed to get a pair of DL650 handguards off ebay last week, £34 delivered and the fixing kit was included. Got 'em fitted in no time thanks to
you guys ! Just need a couple of diff. colour bolts n washers. I might have a go at adding some spoilers as they don't seem to protect the tops of my hands. That said, I'm gonna check to see if I've got the spacing right, they could be a bit out of shape/squidged.
Great tutorial !
you guys ! Just need a couple of diff. colour bolts n washers. I might have a go at adding some spoilers as they don't seem to protect the tops of my hands. That said, I'm gonna check to see if I've got the spacing right, they could be a bit out of shape/squidged.
Great tutorial !
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#67
Sparky
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just half a litre to go
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Posted 16 May 2008 - 10:04 pm
Hartside man gave me another excellent tip regarding these handguards: The right-hand side one is available separately when ordered as a DL1000 V-Strom part, and costs only £12. So if you happen to drop your bike (as I did 
) or for some other reason ruin the RHS guard, you can get a cheap replacement (as I did ). The dealer informed me that the model year is significant because of a slight colour change - I went for the latest (2008) incarnation and the match is perfect. 
This only applies to the right-hand guard. Do NOT attempt to order a separate DL1000 guard for the left, because it has a different shape to fit around the hydraulic clutch reservoir fitted to that model.
Thanks to HM for another top piece of advice.
) or for some other reason ruin the RHS guard, you can get a cheap replacement (as I did ). The dealer informed me that the model year is significant because of a slight colour change - I went for the latest (2008) incarnation and the match is perfect. This only applies to the right-hand guard. Do NOT attempt to order a separate DL1000 guard for the left, because it has a different shape to fit around the hydraulic clutch reservoir fitted to that model.
Thanks to HM for another top piece of advice.
Edited by Sparky, 16 May 2008 - 10:05 pm.
Ex-TDM owner. Now riding a Sprint ST 1050
#68
Geordie Guy
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Posted 21 May 2008 - 10:42 pm
Did mine tonight, followed the tutorial... Spot on..
Chuffed to bits..
Cheers, Ivan
Chuffed to bits..
Cheers, Ivan
I'm a TDM SNOB !!!! "Adventure before Dementia"
Kawasaki GT550, XJ900 Diversion, 2002 TDM 900 , 2008 TDM 900a, 2010 TDM 900a.
Kawasaki GT550, XJ900 Diversion, 2002 TDM 900 , 2008 TDM 900a, 2010 TDM 900a.
#69
Hartside Man
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Posted 22 May 2008 - 03:42 pm
ok i have an update to this
instead of drilling out the clutch side thread, get hold of a 6mm die or die nut and thread the bolt until the first shoulder. then it will fit in correctly and you haven't had to drill the thread.
instead of drilling out the clutch side thread, get hold of a 6mm die or die nut and thread the bolt until the first shoulder. then it will fit in correctly and you haven't had to drill the thread.
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
I have a Ghost S and i'm not afraid to use it !
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#70
Geordie Guy
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Posted 22 May 2008 - 03:51 pm
Thats what I did.
I bought a die set AAAAAges ago, never even tried it untill last night. Loved using it.
Kept all the bits origonal so I can swap it back.
I bought a die set AAAAAges ago, never even tried it untill last night. Loved using it.
Kept all the bits origonal so I can swap it back.
I'm a TDM SNOB !!!! "Adventure before Dementia"
Kawasaki GT550, XJ900 Diversion, 2002 TDM 900 , 2008 TDM 900a, 2010 TDM 900a.
Kawasaki GT550, XJ900 Diversion, 2002 TDM 900 , 2008 TDM 900a, 2010 TDM 900a.
#71
DKM AUTOS
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Posted 23 May 2008 - 07:09 am
As easy as it sounds, i know im just gonna balls it up. Think im gonna ask Baron to give me a hand and then go for ride-out afterwards to try them out - Up for that?! I'll pm you too.
Cant wait to get them on though as the heated grips are doin my head in.
Cant wait to get them on though as the heated grips are doin my head in.
2009 BMW R 1200 GS Adventure - ABS / TCS / TPS / ESA / ASC ' The Beast!'
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1986 BMW K 100 RT - For sale!!
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#72
tdmmark1
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arrived on last train
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Posted 28 August 2008 - 09:27 pm
hi just say that these hand gaurds also fit the 850 and look really good had mine on for a couple of weeks did a three hour ride in the rain and still had dry hands so what you waiting for cheers
#73
Magic
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Posted 11 October 2008 - 06:25 pm
OK I added the DL 650 handguards to my MK1 TDM850 this morning - thanks for to the instructions they were almost perfect for the 850....
Not sure if the kit has changed (mine cost me £29 plus VAT) but you get a grommet to go over the clutch adjuster
On the brake side, the bolt supplied is totally different from the TDM origional
You 'could' drill out the top of the clutch frame and drill out the bush (in the leaver), but the bush is hardened steel, so very difficult to drill, plus REALLY fiddly. I opted (as I had a mate with a lathe handy) to turn down the shoulder of the bolt to fit the bush. (The picture shows the bolt as it was)
I then had to cut down the plastic of the handguard to clear the brake switch under the master cylinder.
I then turned down the bar ends to suit where the handguards were going to hit them (so NOT 4mm in) - this seemed the logical thing to do.
The other thing was the RH guard should sit on top of the bolt and slide underneath the brake housing, but on this set the distance top to bottom of the guard was the same distance as the brake housing, so I just bolted through the lot - seemed to work, but now I am left with the BIG nut on top instead of hidden.
UPDATE: Took it off again and chopped the whole bottom off the guard, so that it sat properly on the bolt - much better dynamics
Anyway - this is what a MK1 looks like with DL650 handguards - can't wait for some chilly weather
Not sure if the kit has changed (mine cost me £29 plus VAT) but you get a grommet to go over the clutch adjuster
On the brake side, the bolt supplied is totally different from the TDM origional
You 'could' drill out the top of the clutch frame and drill out the bush (in the leaver), but the bush is hardened steel, so very difficult to drill, plus REALLY fiddly. I opted (as I had a mate with a lathe handy) to turn down the shoulder of the bolt to fit the bush. (The picture shows the bolt as it was)
I then had to cut down the plastic of the handguard to clear the brake switch under the master cylinder.
I then turned down the bar ends to suit where the handguards were going to hit them (so NOT 4mm in) - this seemed the logical thing to do.
The other thing was the RH guard should sit on top of the bolt and slide underneath the brake housing, but on this set the distance top to bottom of the guard was the same distance as the brake housing, so I just bolted through the lot - seemed to work, but now I am left with the BIG nut on top instead of hidden.
UPDATE: Took it off again and chopped the whole bottom off the guard, so that it sat properly on the bolt - much better dynamics
Anyway - this is what a MK1 looks like with DL650 handguards - can't wait for some chilly weather
Edited by Magic, 16 October 2008 - 11:10 am.
Magic
The bike is faster than the eye or the hand.
Reborn MK1 -rubbish exhaust, dirty engine, missing bolts, missing mirrors, leathal rear tyre, crap carbs - but it doesn't ground out like my old CB750 Custom used to do :-)
Now with DL650 handguards and Garmin Sat Nav
The bike is faster than the eye or the hand.
Reborn MK1 -
Now with DL650 handguards and Garmin Sat Nav
#74
catsbum
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Posted 11 October 2008 - 06:29 pm
Nice post Magic.
And what a loverly neat tool board.
And what a loverly neat tool board.
#75
Magic
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Posted 11 October 2008 - 10:07 pm
QUOTE(CatsBum @ Sat 11th Oct 2008, 07:14 PM) <{POST_SNAPBACK}>
Nice post Magic.
And what a loverly neat tool board.
And what a loverly neat tool board.
It may be a neat tool board, but I still haven't found the tool to get a spark plug out of the TDM
Magic
The bike is faster than the eye or the hand.
Reborn MK1 -rubbish exhaust, dirty engine, missing bolts, missing mirrors, leathal rear tyre, crap carbs - but it doesn't ground out like my old CB750 Custom used to do :-)
Now with DL650 handguards and Garmin Sat Nav
The bike is faster than the eye or the hand.
Reborn MK1 -
Now with DL650 handguards and Garmin Sat Nav
#76
Toraneko
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Posted 28 October 2008 - 05:00 am
QUOTE(AJ.. @ Sat 3rd Feb 2007, 03:08 PM) <{POST_SNAPBACK}>
Looks familier ain't it? 
So AJ, who's the idiot on the Singapore rider's forum who reckon's TDM 900's are shit.
The bloke needs some therapy & IMHO doesn't know anythingabout bikes.
cheers, Shane from Tassie
Airbox Mod ( JBX ), Krauser K-wing mount & Top Box, TDM Shield a.k.a TigerScreen Mk 2, HyperPro progressive rate fork springs, BeoWulf - Warrior exhausts,
Stebel Compact Nautilus Air-Horn with Eastern Beaver relay kit, Eastern Beaver PC-8 switched fusebox, Powerlet BMW style power socket
plus controller & heated gloves for the missus. Oxford v7 Heated Grips, V-Strom 650 HandGuards, Fenda extenda.
Stebel Compact Nautilus Air-Horn with Eastern Beaver relay kit, Eastern Beaver PC-8 switched fusebox, Powerlet BMW style power socket
plus controller & heated gloves for the missus. Oxford v7 Heated Grips, V-Strom 650 HandGuards, Fenda extenda.
#77
simmo
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sticking around
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- TDM model: 1994
Posted 27 November 2008 - 10:14 pm
Fitted DL650 handguards to my MK1 today. Thanks for a great tutorial.
1994 TDM850 (reg 1996), 1984 RZV500R www.rzv.eclipse.co.uk, 1987 CR250R
#78
simont
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arrived on last train
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- TDM model: 2006
Posted 23 January 2009 - 08:45 pm
Finally got the DL650 guards fitted to my 900 and I'm delighted. Big thanks to Hartside Man for the instructions. The throttle side guard is a snug fit against the brake fluid reservoir as has been mentioned elsewhere but a bit of grunting and swearing seemed to do the trick! Oh, and I sprayed WD40 into the machined grooves on the bar end weights to help slide them into place. Worked a treat. Once again, many thanks.
#79
dicky1
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just half a litre to go
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Posted 31 March 2009 - 08:45 pm
I used the Hartside Man's instructions today to fit the DL650 handguards to my 900, unbelievably good instructions made the job a doddle. Well done my man
Now where do i send the royalty fees to 
Now where do i send the royalty fees to
TDM 900ABS, Suzuki DR250 twin-cam off-roader
Hers Honda XL1000, TTR250 off-roader
Hers Honda XL1000, TTR250 off-roader
#80
TDM2340
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discovering Carpe
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Posted 20 May 2009 - 12:49 pm
Thanks Hartside Man. Just picked up a 2008 TDM and will fit the handguards as you have shown.
I like the look of your screen as well. Any details would be appreciated. Tah.
and will fit the handguards as you have shown. I like the look of your screen as well. Any details would be appreciated. Tah.
TDM2340
Black 2008 mod, Ventura rack/bag, tall screen, bar risers, Suzi h/guards, JBX airbox mod 1
Black 2008 mod, Ventura rack/bag, tall screen, bar risers, Suzi h/guards, JBX airbox mod 1
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