Idea for OEM Handguard Nut Issue - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 13 Old 01-10-2008, 08:34 PM Thread Starter
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Post Idea for OEM Handguard Nut Issue

Got my Suzuki handguards tonight. After reading about others losing the nut inside the bars, I tried to follow everyone's instructions on not removing the long screws. I tried everything to wiggle them out, no luck. It felt like I was about to break something.

I gave up and went ahead and took the left side apart, luckily the nut stayed in place, got it assembled.

The right side was not so good. Nut fell through. I had an idea that took me a couple minutes to get me out of trouble...it might help those of you who run into the same problem:

Here is a pic of the rubber 'expansion' washer that holds the nut in place:



Pic of the nut that goes inside the rubber washer (behind the washer):



Since the rubber washer felt like it was glued in the bars, this is what I used to get it out of the bar (pegboard hook):



Insert the pegboard hook into the handlebar through the rubber washer like this, and yank it out:



I used a flexible magnetic retriever to get the nut from inside the bar:



This is what the whole assembly looks like inside the bar:



Note: the instructions SUCK big time. Finished pictures are 2-dimensional. Some of you may end up asking others which bolt should go where.

All the OEM dealers say these handguards will not fit DL650K7 models, mine fit just fine, except the right side needed to bend a little.

Good luck.
Jim

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post #2 of 13 Old 01-10-2008, 08:41 PM
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Amazing! I JUST posted a thread on the exact topic! I did not find that bolt you had to fish out of the right bar. I looked into the handlebar with a bright light and all that I could see was a washer which I had to fish out. Could it still be in there?
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post #3 of 13 Old 01-10-2008, 09:20 PM Thread Starter
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Originally Posted by BarNone View Post
Amazing! I JUST posted a thread on the exact topic! I did not find that bolt you had to fish out of the right bar. I looked into the handlebar with a bright light and all that I could see was a washer which I had to fish out. Could it still be in there?
First thing you see is a washer. Behind that is the rubber piece. The nut is the last thing, and is lost inside the bars. Take a look at the fully assembled pic, that is the order. Gotta get the rubber piece out in order to get the nut out.

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1990 Honda PC800 -sold
2007 DL650 - sold
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post #4 of 13 Old 01-11-2008, 09:33 AM
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Excellent post Green... I wish I saw this a week ago.

I had to use a bent coat hangar... but it worked just the same.

DL650-k5
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post #5 of 13 Old 01-11-2008, 02:39 PM
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If you are having problems getting the bar ends off after loosening (not removing)the bolts, try hitting the end of the weight with the heel of your hand. This will drive the assembly into the bars a little but it loosens the rubber expansion washer a bit and makes it a easier to then wiggle the whole assembly out.
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post #6 of 13 Old 01-11-2008, 04:11 PM Thread Starter
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Quote:
Originally Posted by Colin View Post
If you are having problems getting the bar ends off after loosening (not removing)the bolts, try hitting the end of the weight with the heel of your hand. This will drive the assembly into the bars a little but it loosens the rubber expansion washer a bit and makes it a easier to then wiggle the whole assembly out.
I don't see how that would work...once the screw is loosened, it is still attached to the nut, and the nut slides out of the rubber expansion washer further into the bars....besides, many K7 owners were saying that the expansion washer seemed to be really stuck inside, as if it were glued in place. I did notice that once it came out, it was very easy to slide it back in....so if I took it apart again, it probably will be easy to wiggle out. We will see when I get a cruise control in the near future.

1995 Honda CB750 - sold
2005 Honda Rebel -sold
1990 Honda PC800 -sold
2007 DL650 - sold
2011 DL650A - current
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post #7 of 13 Old 01-11-2008, 06:10 PM
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The nut can't slide off the rubber expansion piece if the screw isn't removed. The screw enters the nut at the small end. It's like the old Chinese finger cuffs we played with as kids. Push and wiggle gets them off. Pulling makes them tighter.

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post #8 of 13 Old 01-11-2008, 09:48 PM
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When I put new grips on, I lost the nut as well. Since I didn't have a flexible magnet, or a long bar to put in the bars, I just too the bars off and got it out. Although it was a bit of over kill, I now know how to remove all the controls. Useful for when I replace the stock bars.

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post #9 of 13 Old 01-11-2008, 11:23 PM
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One tip here, always turn the bike where the handlebars ends are turned down, your nut will not fall uphill. Yes, a coat hanger with a sharp small 90% bent end will pull the tighting plug out. Took me 15min. to do the job.
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post #10 of 13 Old 01-11-2008, 11:28 PM
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I just loosened it up and took a rubber mallet to knock the whole assembly out. Came out after one or two hits with the mallet.

-GW

GrayWolf
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"I wouldn't take a million dollars for the experience, but I sure wouldn't give a red cent to go through it again" -Chester Russell
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