handguards and the retaining nut i couldn't retain - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 7 Old 06-20-2006, 10:51 PM Thread Starter
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handguards and the retaining nut i couldn't retain

So i decided to put some OEM handguards on the Strom today. What a freakin' disaster. The directions weren't as bad as I thought and I was under the impression that I could get the last retaining nut out without too much of a hassle due to my reading the caveats and advice placed on here. Was I wrong. The left side was left in the bar, but I was able to fish it out with a hanger. The right side? No such luck. Not only did it not come out with the rest of the assembly, it was WEDGED in there. I took the handle bars off and managed to lose a chrome cap for the riser bolts as well as a washer for the top of the risers to the nether regions of the underside of the fairing. No, no no, dear reader it was worse than that. I got the handlebars off, and could not get this nut out. I tried compressed air, a rubber mallet on one end and then the other, I tried not 1 but 2 hangers, 10 gauge wire, and so on. Oh yeah and an electrians snake and a plumbing snake. It was JAMMED. The nearest bike shop that had the nut was 73 miles away (and of course it was within 25 mins of closing time, AND i have a huge charity ride tomorrow) and wanted 8 bucks for the nut. I managed to find an old friend (who was my coworker when I worked in a shop and also raced CCS) and he noticed the 1993 Gixxer 1000 used the same assembly. He kept shop open for me til I could get to his place 30 miles away and 25 bucks later I have the assembly. I shot home and reinstalled everything, so far so good, now i am CONVINCED the bars are not in the same position i.e. tilt but my mirrors, etc are showing the same view/perspective as before. . .

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post #2 of 7 Old 06-21-2006, 11:27 AM
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OMG!!!!

Reading your post, I thought I had made the post myself and completely forgot about it. I had to double check your screen name to make sure it wasn't mine. I had the exact same problem, word for word this weekend! :shock: Everything from loosing the second nut, to it getting jammed, to trying all kinds of wires, plumbing snakes, etc. I can't for the life of me understand how it could get so jammed up in there! I even tried squirting a bunch of WD-40 in there and tried heating up that bend in the bars with a hairdryer. No luck. I'm at the point now where i'm just going to leave it and have the dealer use a replacement nut when it goes in for my 600 mile service this weekend.
Oh, and i completely scratched up the bars when i removed them. The nut i lost was on the right hand side. If it was the left hand side, i would have known right away that the nut was jammed in there since the bike is tilted to the left when on the side stand. Since i couldn't tilt the bike to the right to let the nut fall out (yeah, right!!!) i had to remove the handlebars. In the process, the sharp eged handlebar mounts totally scratched a bunch of black paint off the bars. Grrrrrrr!!! :evil:

-dennis
2006 DL650 Silver Blue
2004 Triumph Thruxton
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post #3 of 7 Old 06-22-2006, 08:06 AM Thread Starter
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same here my friend, i'm trying to convince myself that the paint chip in the handlebar give the bike "character!" :roll:

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'06 Red DL650 with some goodies
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post #4 of 7 Old 06-22-2006, 01:06 PM
zady
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Wow, what a nightmare!

I was planning on getting the OEM guards for my Wee, but after reading your stories, I'm definitely having second thoughts.

May be an obvious question, but would you recommend against the OEM guards because of this? Or, now having been through the installation, is there something you could have done differently to make it go smoother?

I'm really curious, because I'm not the handiest person, and I'm definitely not the most patient person, so I think I would have a heart attack if I had the problems you guys had.
post #5 of 7 Old 06-22-2006, 01:42 PM Thread Starter
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well, here's the thing. All my past racebikes had completely hollow clip ons, so i just used the simple LPUSA or IRP bar-ends or sliders on them, never had to worry about the multi-piece system the DL uses. My past street bikes also had threaded inserts that were part of the bars themselves, again, no problem. From what i can think of using 20/20 hindsight, I would just LOOSEN the bar end screw, NOT take it out i.e. loosen a little and pull on the whole bar end, loosen a little more and pull the bar end til the whole thing comes out. FWIW, if you get jammed up, no pun intended, most places stock the GSXR1000 bar end assembly which has that nut, a 24 dollar piece just to get the frikkin' nut, not ONE place in NJ had it in stock ( the nut that is, they all had the GSXR assembly) , and yes, i called EVERY SINGLE SUZUKI dealership in the state!
After doing some research it seems amotostuff.com had a pretty neat set up using acerbis guards and then a completely separate adjustable assembly to CLAMP to the bar, hence no headaches so it seems, however it's pretty pricey. I have no experience with the set-up nor do i know of anyone who has used something similar.

'08 Yellow DL650
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'06 Red DL650 with some goodies
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post #6 of 7 Old 06-22-2006, 02:12 PM
zady
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Quote:
Originally Posted by kneedrachen
From what i can think of using 20/20 hindsight, I would just LOOSEN the bar end screw, NOT take it out i.e. loosen a little and pull on the whole bar end, loosen a little more and pull the bar end til the whole thing comes out.
Yes, I think I've actually read this before. It seems to be the "trick" that keeps coming up.

I'll have to remember it when I get mine.

I know there are other handguards out there, but I really like the look of the OEM's.

Enjoy!
post #7 of 7 Old 06-22-2006, 02:43 PM
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Ya, just do that and you'll be fine.

I never would have thought the bar ends were made in such quirky way. You'd think i would have figured it out after i removed the first one. :roll:

-dennis
2006 DL650 Silver Blue
2004 Triumph Thruxton
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