'08 DL650 Suzuki hand guards - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 12 Old 04-14-2008, 12:05 PM Thread Starter
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'08 DL650 Suzuki hand guards

Last night, I installed the OEM hand guards on my '08 Wee. For the (searchable) record, I just want to state that the directions are horrible. Absolutely horrible.

Not only are they brief and lacking details, they're also wrong. They make references to the wrong washers for the wrong steps, don't mention some of the nuts at all, and skip over important parts of the actual installation. The pictures are supposed to fill in those gaps, but not everyone is familiar with 2D CAD drawings.

Thankfully I have common sense and was able to do the job right. However, if anyone is struggling with these, please let me know and I'll be happy to provide any help I can.

2008 DL650 a.k.a. Road Warrior, member #16 of the Flat Black Club
2009 Aprilia Tuono 1000R a.k.a. Silver Thunder
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post #2 of 12 Old 04-14-2008, 12:25 PM
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Well....

Mine are out for delivery as I type this so I will probably be installing them tonight. Any suggestions would be greatly apreciated

2008 VStrom DL1000
2008 VStrom DL650 ABS #09 -Gone but not Forgotten-
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post #3 of 12 Old 04-14-2008, 01:57 PM Thread Starter
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I don't have the directions in front of me, but I'll try to describe the key issues.

1. The left side gets the clutch pivot bolt that has the screw protruding on top. The right side gets the brake pivot bolt that has the screw hole on top. The directions mention that correctly, but make sure to put the right one in the right place. The brake pivot bolt might have to be screwed in through the bottom hole of the brake bracket, it wouldn't just slide through on mine.

2. The left clutch side gets the "spacer" on the bottom of the pivot bolt, as the directions say. BUT.. they tell you to put the washer "G" under the spacer, which you get 5 or 6 of. It does NOT fit. You also get one smaller washer, I think it's "H", which WILL fit under the clutch, so that's the one I used. So on goes the little washer, then the spacer, then you reuse the nut from the original pivot bolt. The right brake side does not get a spacer, just reuse the nut from the original right pivot bolt.

3. Do NOT take the screw out all the way out of the handlebar weights. Unscrew it pretty loose, but pull out the whole assembly out at once. My right one just came right out, my left one was jammed in there. I actually had to take the screw out all the way on the left side, and then used just the screw to pull out the little rubber end piece that was wedged in the handlebars. Luckily it didn't fall into the handlebars like some people report.

4. Putting on the actual guards is pretty simple.

The left side goes onto the pivot bolt on both the top and the bottom. You put one of the large washers "G" on top of the guard and then use the little top screw to tighten it. The bottom gets a washer "G" under the guard and then one over the guard. finally tightened with the nut "M" that's provided in the kit but not mentioned in the directions.

The right guard is a bit trickier. The top goes on top of the pivot bolt and you secure it with the screw provided. The bottom fits over the SIDE of the original pivot bolt nut, so you should make sure it pops on it cleanly, you may have to knock it into place as it's pretty tight. You then put a washer "G" over the bottom and use the supplied nut "M" to tighten that down.

I'm at work so I don't have the bike or the directions in front of me, but I believe that covers the key pain points. The references to the big "G" washers and the small "H" washer were wrong, and the screws "M" were not mentioned at all, but seen in pictures.

Good luck, and let me know if I remembered something wrong, or even did something wrong

2008 DL650 a.k.a. Road Warrior, member #16 of the Flat Black Club
2009 Aprilia Tuono 1000R a.k.a. Silver Thunder
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post #4 of 12 Old 04-14-2008, 10:35 PM
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I agree.

The handgaurd directions are pretty bad. At least there not in German, or italian or brail. I usually just try to free ball it. I work rigging boats and nothing ever fits right, or can be installed with the hardware there give you it seams. It is great though to have good people to help you through certain installs..... Keep on wrenchin...

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Past 2007 ZZR600, 2004DRZ400, 2002 Bandit 1200, 1998 YZF400, 1996 DR350, 1980 Yamaha MX100
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post #5 of 12 Old 04-14-2008, 10:47 PM
 
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Quote:
Originally Posted by Mr.Metal View Post
Last night, I installed the OEM hand guards on my '08 Wee. For the (searchable) record, I just want to state that the directions are horrible. Absolutely horrible.

Not only are they brief and lacking details, they're also wrong. They make references to the wrong washers for the wrong steps, don't mention some of the nuts at all, and skip over important parts of the actual installation. The pictures are supposed to fill in those gaps, but not everyone is familiar with 2D CAD drawings.

Thankfully I have common sense and was able to do the job right. However, if anyone is struggling with these, please let me know and I'll be happy to provide any help I can.
I installed mine last week and have the exact sentiment.
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post #6 of 12 Old 04-16-2008, 03:36 PM
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I had them on my "07 DL650 and want to re-install them. Unfortuneately, I have lost three items. The dear Suzu dealer told me they can only sell me a complete new set and that they have no parts breakdown for them. Anyway, I need the "D" spacer, "G" washers, and "J" Screw. Anyone know how I can get them? Can I sub something else in place of them? Thanks
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post #7 of 12 Old 04-17-2008, 01:40 AM
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See if any DL1000 parts look like they will work. The throttle side is the same but the clutch side is different. http://fiche.ronayers.com/Index.cfm/.../HANDLE_LEVER_
http://fiche.ronayers.com/Index.cfm/...KNUCKLE_COVER_

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
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post #8 of 12 Old 04-17-2008, 12:03 PM
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Greywolf, thanks for the link. It's the size of that spacer that is really my problem. If I knew it's length, I might be able to just use washers, hose, or try to find a spacer at a hardware store assuming the inside is the same size as a washer.
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post #9 of 12 Old 04-17-2008, 03:48 PM Thread Starter
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Quote:
Originally Posted by mhoffm View Post
Greywolf, thanks for the link. It's the size of that spacer that is really my problem. If I knew it's length, I might be able to just use washers, hose, or try to find a spacer at a hardware store assuming the inside is the same size as a washer.
I will try to figure out some measurements for you later tonight when I get home. I have the directions which I believe list the parts and dimensions. I can also measure the spacer if necessary. Stay tuned

2008 DL650 a.k.a. Road Warrior, member #16 of the Flat Black Club
2009 Aprilia Tuono 1000R a.k.a. Silver Thunder
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post #10 of 12 Old 04-18-2008, 12:22 PM
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Originally Posted by Mr.Metal View Post
I will try to figure out some measurements for you later tonight when I get home. I have the directions which I believe list the parts and dimensions. I can also measure the spacer if necessary. Stay tuned

Much apreciated...
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