TDM900 : Fitting Suzuki hand-guards


Right then, first you need to buy the Suzuki DL650 VStrom Hand-guard kit (around £22 from Suzuki)

How-to

(image)Next step is to get your bar end weights off and machined to these dimensions.

(image)On the throttle side remove the existing lever pivot bolt and replace with this one from the kit.

(image)Then insert it like this (this is a threaded straight swap for the original one).

(image)Offer up the hand-guard securing it with the supplied Screw and Washer at the top.

(image)Then fit a supplied lock-nut and washer on the bottom like this.

(image)And clip the other end into the machined groove like this (may need to alter the hydraulic reservoir along the bar slightly to line up) that's the throttle side finished.

(image)Right now onto the clutch side, remove the original pivot pin then get a 6mm drill and remove the thread from the bottom of the lever pivot hole (this is needed as the suzuki supplied bolt is a set thread).

(image)Then insert this lever pin from the kit.

(image)

(image)Clip the handguard over the top of the stud.

(image)And Secure using the dome nut and a washer.

(image)There is a spacer that you need to fit on the underside (I also used a washer top and bottom of the plastic hand-guard) and secure with another lock-nut (supplied).

(image)

(image)Clip the other end into the Bar weight.

(image)Optionally you can fill up the groove with silicon (like i did).

Finished !

Thats it your all done and here are some pictures of the finished job (click to enlarge).
(image) (image) (image)
(image) (image) (image)
(image) (image)

Jobs a Carrot !
Cheap and easy alternative to the BMW ones.

An excellent tutorial from Hartside Man / Carpe-TDM Forum.

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