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Discussion Starter #1
I finally completed the handelbar mods on my new DL650 and I thought I'd throw a picture up here to give folks ideas if they want to change their bars. Although the stock bars worked Okay, really wanted something a little more dirt-bikish and less "ape hangers".



Here's the stuff:

Protaper Pastrana/FMX alum bar (black)
TAG fatbar adapters (black)
Suzuki OEM hand guards
BMW sport grips
Symtec grip heaters
Kaoko throttle lock
Stock bar end on left
Moose alum-bar bar ends (to get split wedges for the alum bar)
KTM Duke II mirrors

The only tricky part was getting the Kaoko to work with the alum bar which has much thicker wall thickness than the stock steel bar. I drilled the end of the bar with an 11/16" drill about 3/4" in to allow the Kaoko to mount. This required a $45 drill bit in a drill press and about the time I had it deep enough, I started having problems with getting a smooth cut.. If you want to mount a Kaoko to an alum bar, I'd suggest you see if you could get a machinst to turn down the Kaoko rather than drilling the bar. The moose bar end kit is needed to be get a smaller "wedge" device to fit to the the Kaoko and stock bar end to get them to mount to the thicker alum bar.

The most time consuming part of the whole thing was finding the damn heated grips connector (buried right in front of the airbox on mine) and working all the wiring to this point. It would have been much easier if I had been able to remove the airbox, but I don't currently see how you get to the front cylinder hose clamp that mates the TB to the airbox. If anyone knows how to get to this clamp, I'd like to hear about it for the eventual TB sync.

- Mark
 

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Discussion Starter #3
Yes, or grind off the indexing tabs. I prefer the positive indexing, so I drilled the small holes.

- Mark
 

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I agree, it turned out real nice! I'm lazy though, and am thinking of going with the SE bars which should provide the same thickness of the stock handlebars. Yours look great, though, real clean install.
 
K

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Re: from lock to lock

vancer said:
Do your bars or switch gear units hit the fairing or tank at full steering lock?
+1 I'd love to know. My SE bars should arrive Tusday, and they are about the same bend.
 

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Looks very clean Mark well done my man


Ok how about comfort , my 2006 DL-1000 even with the stock bars adjusted the best i can tugg on my upper shoulders and back just a touch to much.

I was thinking of maybe these bars with a very mininal bar back set up


Cheers Dale 8)
 
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