92 replies to this topic

[Hartside Man]

PLease follow this link for JBX's site http://jbx9.free.fr/...ex.php?page=HGS my pictures have vanished over time



Can this possibly be posted to the Knowledgebase ? Please mr mod's

Right then, first you need to buy the Suzuki DL650 VStrom Handguard kit (usually 22 UKP from a dealer)

Next step below is to get your bar end weights off and machined to these dimentions



On the throttle side remove the existing lever pivot bolt and replace with this one from the kit



then insert it like this (this is a threaded straight swap for the origonal one)



Offer up the handguard securing it with the supplied Screw and Washer at the top



Then fit a supplied locknut and washer on the bottom like this



And clip the other end into the machined groove like this (may need to alter the hydraulic resovoir along the bar slightly to line up) that's the throttle side finished



right now onto the clutch side, remove the origonal pivot pin then get a 6mm drill and remove the thread from the bottom of the lever pivot hole (this is needed as the suzuki supplied bolt is a set thread )

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.



then insert this lever pin from the kit




Clip the handguard over the top of the stud



And Secure using the dome nut and a washer



there is a spacer that you need to fit on the underside (I also used a washer top and bottom of the plastic handguard) and secure with another locknut (supplied)




Clip the other end into the Bar weight



Optionally you can fill up the groove with sillicon (like i did)



Thats it your all done and here are some pictures of the finished job










Jobs a Carrot Cheap and easy alternative to the BMW ones.

Edited by Hartside Man, 13 April 2012 - 06:33 pm.

[robelst]

Heyhey, well done
Making this groove in the weights is brilliant, it's just the proper way to do it.

I must say they look even better on the 900 than the more "rounded" 850.
But if I buy a 900 to match it wouldn't be a cheap option anymore

I'm glad I've got mine on (albeit fitted in McGuiver-style), just before the sudden weather change: It's still cold of course but you can clearly feel the difference while still wearing my "Autumn-gloves" on my 20 miles commute.

[phoneman]

That's a neat job, thanks for the info. I wish I hadn't bought Cycra 'guards last week!!

[jht]

Are the DL ones as big as the 1150GS ones??

Cracking tutorial, can I send some of my lecturers to you for some tutorials on giving tutorials??

[Hartside Man]

Are the DL ones as big as the 1150GS ones??

Cracking tutorial, can I send some of my lecturers to you for some tutorials on giving tutorials??

dunno on the first bit, try comparing photo's and make up your own mind

nope no letchers here

[OF.uk]

Excellent job Mark, but where do I get the end weights machined and how much is it likely to cost me?
Cheers.
Paul.

[Hartside Man]

Excellent job Mark, but where do I get the end weights machined and how much is it likely to cost me?
Cheers.
Paul.

you must know someone who has access to a lathe Paul ask around a bit, i am sure you will find someone (maybe dave fud ?) anyway if not, visit your local machinist and ask very nicely

mine cost me 2 rollies and a bag of chips

[jht]

nope no letchers here

Ohhh yes there are.....

[dapleb]

Nice work amarko.

Is the silicon doing a job of holding the clip into the machined groove, or preventing rattle?

Did you machine them yersen or get someone else to do it? If someone else did it, just wonderin if you have a price for those that may loike to do this mod.

[Hartside Man]

Nice work amarko.

Is the silicon doing a job of holding the clip into the machined groove, or preventing rattle?

Did you machine them yersen or get someone else to do it? If someone else did it, just wonderin if you have a price for those that may loike to do this mod.

the clip fits quite nice on the 17mm (suzi provided ones were a tad slack at 16mm) and yes i felt the silicone would also (glue it in place) whilst being easy to remove and redo if necessary)

regarding the weights any local machine shop should be able to whip them up for you in 10 mins or so. I could ask my local guy if he can, but i feel the weight of them would make it expensive posting each way

If i still had access to a lathe i could do it in minutes (unfortunatly thats a no go where i currently work) no lathe anymore , no miller , in fact bugger all. doing jobs at work is like scrapheap challenge

[Landy]

What an excellent job, looks great. One thing does strike me though, if you used black sealant (I know most of us would only have clear or white handy in the shed) then the grove would be almost invisible.

[Hartside Man]

What an excellent job, looks great. One thing does strike me though, if you used black sealant (I know most of us would only have clear or white handy in the shed) then the grove would be almost invisible.

indeed but as you suggested I only had clear to hand

its easy removed but i aint noticed black silicone on my travels will have to look into that one

[Landy]

Those nice folks at Screwfix do some in a small tube only £2.50 = cheep, at least until you find all those other bits and bobs to further clutter the shed up with.

Edited by Andy K, 26 January 2007 - 12:34 pm.

[Hawmaw]

After reading this I quite fancy a pair of these guards so I dropped into Mickey Oates motorcycles in Glasgow today and had a look at them on a 650 VStrom.

I was particularily interested in the Suzuki bar ends and spacers which would seem to be an easier and quicker option than getting a pair machined.

I just about keeled over when the girl in the showroom looked up the price

£22 EACH !!!

I think I'll find someone with a lathe.

[Hartside Man]

After reading this I quite fancy a pair of these guards so I dropped into Mickey Oates motorcycles in Glasgow today and had a look at them on a 650 VStrom.

I was particularily interested in the Suzuki bar ends and spacers which would seem to be an easier and quicker option than getting a pair machined.

I just about keeled over when the girl in the showroom looked up the price

£22 EACH !!!

I think I'll find someone with a lathe.

Or if you cannot find a Lathe robelst has another method of fixing in this thread http://www.carpe-tdm...o...=2766&st=71

[AJ..]

Looks familier ain't it?

[Pict]

Those nice folks at Screwfix do some in a small tube only £2.50 = cheep, at least until you find all those other bits and bobs to further clutter the shed up with.

Hellfires also do black silicon in 40g tubes - for windscreens etc. Sorry - can't recall the price but I bought some so it must be relatively cheap

Neat job on the guards and a model piccy set.

[BigC]

thanks to Hartside Man for this excellent tutorial.

handguards are now fitted to the bike although still waiting on the bar ends comming back from the machine shop.



i didnt fancy drilling my new bike as suggested:
"the clutch side, remove the origonal pivot pin then get a 6mm drill and remove the thread from the bottom of the lever pivot hole (this is needed as the suzuki supplied bolt is a set thread )"

so instead went to my local hardware shop ("modern screws" - love the name!) and tryed to get a new bolt. couldnt get one long enough so went for a threaded rod and cut this to length. then was a simple case of bolts and washers at the top and bottom.

jobs a good 'un. no drilling of the bike and only cost a couple of quid (shop has a minimum £3 charge).

also decided to cut a small notch out the the handguard on the throttle side to ease fitting as they were pushing too close against the cables (see photo 4 on tutorial).

[Hartside Man]

thanks to Hartside Man for this excellent tutorial.

handguards are now fitted to the bike although still waiting on the bar ends comming back from the machine shop.
i didnt fancy drilling my new bike as suggested:
"the clutch side, remove the origonal pivot pin then get a 6mm drill and remove the thread from the bottom of the lever pivot hole (this is needed as the suzuki supplied bolt is a set thread )"

so instead went to my local hardware shop ("modern screws" - love the name!) and tryed to get a new bolt. couldnt get one long enough so went for a threaded rod and cut this to length. then was a simple case of bolts and washers at the top and bottom.

jobs a good 'un. no drilling of the bike and only cost a couple of quid (shop has a minimum £3 charge).

also decided to cut a small notch out the the handguard on the throttle side to ease fitting as they were pushing too close against the cables (see photo 4 on tutorial).

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

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

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

just my thoughts as an engineer