Installing Suzuki Handguards - DL650 - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 9 Old 10-30-2008, 10:39 PM Thread Starter
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Installing Suzuki Handguards - DL650

This is a great upgrade and worth the trouble, but it is a real pain to install them. The directions are useful only for the diagrams, which are themselves confusing. They leave out a bunch of steps and were clearly written by an idiot.

However you will figure it out - one key trick is when you remove the bar ends, don't back the screw out all the way - keep the assembly together and wiggle it out. It takes a while and a lot of force, but it'll come out.

In the process I learned how the brake lever and clutch levers go together and work. And I will say, once installed they are on there pretty good.
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post #2 of 9 Old 10-30-2008, 10:47 PM
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From experience if your long bolt on the bar end does come loose from the rubber stopper, use a an air compressor on the opposite end to blow it out. Aim it at a wall cuz that sucker will fly!

[SIZE="1"]SOME PEOPLE ARE LIKE SLINKIES - NOT REALLY GOOD FOR ANYTHING, BUT THEY BRING A SMILE TO YOUR FACE WHEN PUSHED DOWN THE STAIRS.[/SIZE]
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post #3 of 9 Old 10-31-2008, 08:08 AM
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coincidentally I just ordered the handguards yesterday from Oneida.. with shipping not that great a savings but it saves me from driving to a store that might not even have them....

anyway, any other advice for the install??

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post #4 of 9 Old 10-31-2008, 09:23 AM
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Be patient! My nuts got stuck in the handlebar when I tried to blow them. Had to resort to a coat hanger, flashlight and beer to get them out. Putting everything back together is a breeze.

[SIZE="1"]2006 V-Strom 650, 2005 KLR 650 (Sold), 1998 KLR 250 (Sold), 2000 Kymco Cobra Racer (Sold, it was a scooter - does that count?), 1978 YZ125 (Sold), 1989 KX 125 (Sold), 1984 DR 125 (Sold), Misc Mopeds (Sold)[/SIZE]
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post #5 of 9 Old 10-31-2008, 09:33 AM
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Quote:
Originally Posted by DblD View Post
My nuts got stuck in the handlebar when I tried to blow them.
Don't anybody else try that. :rofl:

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post #6 of 9 Old 10-31-2008, 09:49 AM Thread Starter
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The problem is they leave out a lot of steps. The bolt with the big hexagonal piece is the brake lever replacement pivot bolt, and the bolt with the nut already on it replaces the clutch lever pivot bolt.

On the LH bar, once you replace the clutch lever bolt with their bolt, you add the spacer, washer and locknut underneath and then tighten. The top hole in the handguard sits around the nut that comes on the top of the bolt. Then you put a washer on top of that and the crown nut on top of that. Underneath, you add a washer and regular locknut. I figured this out from looking a the diagram and from using common sense, but it was frustrating.

On the RH bar, you have to remove the brake lever - do not be intimidated, you can't really put it back together wrong. You will have to move the throttle cables up and out of the way, but you don't have to detach them. The "cap screw" (I don't know what the technical term is) secures the top handguard hole and the bottom is just another washer/locknut assembly.

I found the bar end weights to be the easier part of the install. Again, don't back the screw out all the way - just far enough to get a good grip on the assembly. Wiggle and pull, it will start moving.
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post #7 of 9 Old 10-31-2008, 12:32 PM
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Quote:
Originally Posted by DblD View Post
... My nuts got stuck in the handlebar when I tried to blow them...
Dude... this is a family forum, you really shouldn't share things like that... :mod_biggrin:

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post #8 of 9 Old 11-05-2008, 07:19 AM
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oh I hate it when that happens. very embarassing.
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post #9 of 9 Old 11-05-2008, 02:26 PM
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Quote:
Originally Posted by DblD View Post
Be patient! My nuts got stuck in the handlebar when I tried to blow them. Had to resort to a coat hanger, flashlight and beer to get them out. Putting everything back together is a breeze.
Ouch - but what about installing the handguards?

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