Two Cracked/Broken Engine Guard welds - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 6 Old 04-09-2015, 03:24 PM Thread Starter
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Join Date: Aug 2007
Location: Kennewick, WA
Posts: 16
Two Cracked/Broken Engine Guard welds

I did a quick search for re engine guards but only found new ones (Givi/SWMotech) which is not my topic. Redirect the thread please if I missed existing.

I have the 2012 A model with panniers and OEM engine guard. Thinking about going to SW Motech guards, but first want to check out the problem.

Forest service roads were bad last year. Corrugated & washed out to Mt Adams areas I frequent. Result: Cracked then welded bolting tab on left side. Two months later cracked weld at the joint with the lower crossover branching from the right side.

I suspect some stresses from misaligned halves of the assembly. Both times it cracked the released pieces jumped 1/4" out of alignment. When I welded the first problem I assembled it while slowly torqueing in a round the world sequence trying to get it balanced out, but obviously to no avail.

Never crashed.

Anyone else had the problem? What adapters, shims, or spacers worked to fix the misalignment?

Ride well.

Last edited by Longshadow; 04-09-2015 at 03:30 PM. Reason: ID Bike
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post #2 of 6 Old 04-21-2015, 10:11 AM Thread Starter
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Join Date: Aug 2007
Location: Kennewick, WA
Posts: 16
Ten days, no feedback. Guess I'll just cut the cross bar off for this season's highway tours, then replace the whole thing. I'll check in when I return in September to pick the best replacements.

Ride well.
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post #3 of 6 Old 04-21-2015, 10:47 AM
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Join Date: Oct 2009
Location: Bay area, ca
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I would guess that this is a rare occurrence and anyone that's had or heard of your problem has not seen your post.
You may have a unit that just wasn't jiged up correctly. Instead of a cross bar removal, I'd weld some flat or oversize round stock on leaving the 1/4" gap in place for a temporary solution if aesthetics aren't important to you. Some pics here would help

'09 VEE
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post #4 of 6 Old 04-21-2015, 02:00 PM
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Location: Okanagan Valley, British Columbia
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My Alt Rider bars use a solid rod to join the two halves together. Rather than cut away the cross bar completely, cut, insert appropriately sized alum rod and drill then bolt through the bars and rod. I think cutting away the cross bar completely would reduce strength a lot.
Here is the Alt Rider bars. Crash Bars for the Suzuki V-Strom DL 650 AltRider

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post #5 of 6 Old 04-23-2015, 07:23 AM
Join Date: Jul 2008
Location: Brisbane Australia
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remove the cross bar and your crash bar will almost bent like butter on the first drop.

Perhaps get someone cut and reweld the cross bar with the crash bar (halfs) correctly installed on the bike - that will take out any misalignment and static forces inherent in it.

L2 Glee;


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post #6 of 6 Old 04-23-2015, 10:23 AM
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I had the same problem on my Glee. Fortunately, the crash bars were replaced under warranty. No problems in 40K miles since the replacement. I wonder if there was a bad batch. If you look closely at the welds, they are pretty badly done.

L2 DL650 Adventure

bike X miles=smiles
smiles bike=miles
smiles miles=bike.
It's simple math.
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