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So I love the look and the clean install of the DL650 specific handguards from Suzuki, but like many I was a bit concerned about ruggedness of the all plastic design. So here's a simple mod that (I hope) will add enough beefiness to the guards to protect clutch/brake arms from busting off if the bike decides to throw itself to the dirt.

I bought a 3 ft piece of 1"x1/8" aluminum flatbar for a couple bucks at local hardware store. I used a hammer and an anvil-like-surface (similar to my rock hard abs :)) to pound it into the desired shape. I then drilled a couple small holes and put a couple small bolts through (with locktite) to keep the pieces together. Drilled larger hole near end for bar end bolt to go through. Removed bar ends, slipped on the flatbar, replace bar ends and tightened down. Done.

I considered putting the flatbar on the outside of the handguards, but didn't because I liked the clean look of it being on the inside. I suppose its debatable as to whether it will be as effective on the inside, but my main goal isn't to protect the handguards, its to protect the clutch arm from breaking and leaving my stranded somewhere.

The reason I used to pieces of 1/8" thick rather than a single 1/4" is that its a heck of a lot easier to bend 1/8" thick material. I also fully expect the flatbar to bend a bit when hit hard, but I think this is desirable - it helps absorb any impact. Frequently people over-engineer things so they never bend - but that just means that something else will probably end up breaking - perhaps something more expensive.
 

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Good job, I am thinking about doing the same but would probably make it longer and extend the entire length of the guards. I need a couple of weeks of lifting weights to be able bend the metal first.
 

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Cheap and sacrificial to save other stuff sounds good.
 

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Good job, I am thinking about doing the same but would probably make it longer and extend the entire length of the guards. I need a couple of weeks of lifting weights to be able bend the metal first.
Yeah, I wanted to have it totally wrap around the inside, but there isn't a lot of spare room between the guard and the clutch handle. I think that with the proper tools one could shape the flatbar to go around the outside of the guards and look pretty good. I just have a crappy tool supply.
 

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Won't that rotate and stab your leg or the gas tank if you fall?

I for some reason have a hard time believing that won't at least ben inwards and smash your fingers binding them to the clutch lever.... :confused:
 
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