PDA

View Full Version : DL650 Hand Guards on a 600 Bandit


Ken Phenix
11-28-2007, 10:41 PM
Thanks Brass for posting your hand guard pics. Here's my experience installing them on my 2000 GSF600S.

I ordered the kit from:
http://www.prosourceoutlet.com/pages/catalogs/detail/35/351/775/15669/1/0/0/0/0/0/0/0/hand-guard-set.aspx

I started on the throttle side which was a snap. The only change I had to make was to flip over the brake lever adjuster pivot bolt because the nut on the bottom rubbed the guard. I did not have to modify the right guard at all.

Ken Phenix
11-28-2007, 11:02 PM
On the left side, I started by removing the clutch lever (don't forget to pull the clutch safety switch first). I lined up the guard and marked the spot for a 3/8" hole for the clutch cable to go through. I did not want to remove any more material from the guard than was necessary. One 3/8" hole is the only modification I had to make to the guard itself.

The safety switch (or its plug) was in the way so I added a couple of washers on the bottom mount. I had to cut off the safety switch plug and solder the wires directly to the terminals on the switch and only then had just barely enough clearance.

The rest of the pics are still in the camera at the office. I'll finish this tomorrow.

Ken Phenix
11-29-2007, 09:07 AM
I had to trim about 1/3 off the terminals. Then I soldered the wires on and covered the terminals with a piece of shrink tube filled with silicone gasket sealer. So the left side was a bit of a pain but not too bad.:rider:

There are no real clearance problems. The right side barely touches the mirror and the left one touches the top corner of the windshield. I can move the bars back a little or I could use this as an excuse to justify a new windshield.:trust:

GregH
11-29-2007, 10:10 AM
Nice post, Ken. Thanks for the pics and the details.

Ken Phenix
11-29-2007, 10:40 AM
Nice post, Ken. Thanks for the pics and the details.

That's why I love all the information sharing that goes on in these forums. This is something I have been wanting to do for a while but was afraid to risk the 50 bucks until I saw the report posted by Brass.

Brass
11-29-2007, 02:14 PM
With your cable clutch the install looks like it was pretty easy.

If you rotate your bars back a little in their clamps, the guards should clear windshield but then you wouldn't have a reason to change the shield. Just be careful you don't rotate them so far back that they touch the tank when fully turned.

Make sure you post what you think of them once you've been out for a few rides.

Ken Phenix
12-02-2007, 08:15 PM
I discovered a side benefit to the hand guards today. I got caught in the rain and
. . . . . waterproof touring jacket - check
. . . . . . . . . . old rainsuit pants - check
. . . . . . . . . . . . . . . . waterproof gloves - nope.
I ducked into the the first drive-thru bank canopy and closed my jacket vents and put on the rainpants. After my 13 mile ride home I discovered my hands were still dry. Cool! The hand / rain guards deflected enough of the wind and rain to keep my gloves from getting soaked.:rider:

kurt
12-02-2007, 08:26 PM
Just disable the clutch switch. Most bikes don't even have one. Cut the plug off and solder or crimp the ends together. I did that to my Bandit and never had any issues. A grommet where the clutch cable goes through would look good too.

Ken Phenix
12-02-2007, 09:25 PM
Just disable the clutch switch. Most bikes don't even have one. Cut the plug off and solder or crimp the ends together. I did that to my Bandit and never had any issues. A grommet where the clutch cable goes through would look good too.

Thanks, I had the bypass loop complete with spade terminals all ready to go and decided to try to keep the switch at the last minute. I like the grommet idea too. I'm also thinking about hiding a PTT button inside the left guard.

rrrr
12-14-2007, 11:38 AM
Just put a set on my 07 Bandit 1250. Worked great only had to trim the right guard a little for the throttle cable. The left side didn't need any attention because I have the hydraulic clutch. The kit is great and easy to follow. Took me about 30 minutes to do. I'm going for a ride this afternoon the high temp should reach 34f, we'll see how they work!!


Ray

2007 Bandit 1250
2005 GSXR 1000
2005 Harley Electra Glide
2003 Kawasaki Kx 250

GregH
12-14-2007, 01:23 PM
Just put a set on my 07 Bandit 1250...
But where are the pics? :confused:

PhilS
12-14-2007, 08:27 PM
Well..............as it turns out, there is a box from Ron Ayers under the Christmas tree (wrapped of course) that has the DL1000 Hand Guard kit with all the mounting stuff in it ready for me to open and act surpised about on Christmas morning. Amazing what you can find out by checking the bank activity online!!!:eek2:

I will have these installed by the end of the day on Christmas on the 1250 with full pictures as you can imagine.

I know, I know - I'm a sloth for cheating and looking and knowing my gifts ahead of time. But at least I don't have to go buy them for myself now!!:trust:

See ya in 11 days.......with warmer hands!!!

Phil

rrrr
12-15-2007, 11:28 AM
But where are the pics? :confused:


Here's the picture with the handguards, GPS, Powerbronz windscreen.

Guards worked well until the sun went down and temps dropped into the 20's. I was wearing medium weight gloves with liners. Heavy weight glove probably would have kept my fingers warm, we'll see. The windscreen definitley was an improvement. Wind was just catching the top of my helmet at 70mph along with my shoulders.

You do loose some turning ability due to the handguards hitting the fairing, its more pronounced for right turns.

GregH
12-15-2007, 12:00 PM
The pics look good, Ray. Now I believe! :mrgreen:

Ken Phenix
12-15-2007, 05:27 PM
Yep, nice pics Ray.

The MRA TouringScreen arrived the other day. I've had no time to play with it though, the Christmas rush is upon us at the bakery. At a glance the new screen will not help my hand guard clearance issue either. It's not serious anyway, just barely touches the right mirror and puts a little pressure on the upper left corner of the stock windscreen. I believe I can pull the bars back enough for everything to clear. Stay tuned, pics to follow.

PhilS
12-15-2007, 05:36 PM
.........You do loose some turning ability due to the handguards hitting the fairing, its more pronounced for right turns.

Eek Gads! :eek2:

I put the BikeMaster Daytona bars on mine and the pull back is a bit less - so in theory, the handguards will hit the fairing/windshield even sooner. Although, when riding the bars are never really turned that much - it's only when maneurvering at parking speeds that may be a problem.

We'll see on the 25th when I get them officially.

Phil

Thanks Ray for the shots. Nice bike.

treybrad
12-15-2007, 06:50 PM
Here's the picture with the handguards, GPS, Powerbronz windscreen.

Guards worked well until the sun went down and temps dropped into the 20's. I was wearing medium weight gloves with liners. Heavy weight glove probably would have kept my fingers warm, we'll see. The windscreen definitley was an improvement. Wind was just catching the top of my helmet at 70mph along with my shoulders.

You do loose some turning ability due to the handguards hitting the fairing, its more pronounced for right turns.

rrrr - Can you post up more pictures of your GPS mount? I've got a 2610 too, and Santa is bringing me a RAM mount and wiring kit. Is yours a RAM? Short arm or regular length?

trey

rrrr
12-16-2007, 02:56 PM
rrrr - Can you post up more pictures of your GPS mount? I've got a 2610 too, and Santa is bringing me a RAM mount and wiring kit. Is yours a RAM? Short arm or regular length?

trey


Here's the info on the mount.
RAM Handlebar Mount for Garmin StreetPilot 2610, 2620, 2720, 2730, 2820 Part Number: GR26H
Price: $39.00 Quantity: 1 Total: $39.00


Motorcycle 12v Hardwire Cable Kit for Garmin StreetPilot 2610, 2620, 2720, 2730, 2820 Part Number: GC12V26
Price: $29.00 Quantity: 1 Total: $29.00


Sub Total: $68.00
Shipping: $7.69
Tax (MO): $0.00
Total: $75.69

Here's the link:

http://www.cycoactive.com/gps/gps2610.htm

I have the same setup on my harley and just swap out the GPS!

The arm is 3.5inches from ball center to center

treybrad
12-16-2007, 05:17 PM
Here's the info on the mount.
RAM Handlebar Mount for Garmin StreetPilot 2610, 2620, 2720, 2730, 2820 Part Number: GR26H
Price: $39.00 Quantity: 1 Total: $39.00


Motorcycle 12v Hardwire Cable Kit for Garmin StreetPilot 2610, 2620, 2720, 2730, 2820 Part Number: GC12V26
Price: $29.00 Quantity: 1 Total: $29.00


Sub Total: $68.00
Shipping: $7.69
Tax (MO): $0.00
Total: $75.69

Here's the link:

http://www.cycoactive.com/gps/gps2610.htm

I have the same setup on my harley and just swap out the GPS!

The arm is 3.5inches from ball center to center

Thanks. That's the exact same kit I'm getting from Cycoactive too, so I guess it'll work just fine.

trey

prhaussies
12-16-2007, 05:18 PM
I just placed an order for a set. Since I have a DL 650, they should fit just right. Sometimes you just need to buy your own presents. ;-) RH

Gilk51
12-16-2007, 06:13 PM
I just placed an order for a set. Since I have a DL 650, they should fit just right.

:eek2: Buying DL650 hand guards for a DL650? :eek2:

What will they think of next? :doh:

-------

I am a firm believer that the guards work - get used to them in the cold and then take them off and try it - you will be a believer, too!

Brass
12-16-2007, 09:00 PM
You do loose some turning ability due to the handguards hitting the fairing, its more pronounced for right turns.

If you trim the clutch side guard down to clear the master cylinder and reposition the mounting hole you should be able to clear the fairing. I had no problems at all on the throttle side. The set I installed clears by about 1/4 inch at full lock in both directions.

PhilS
12-25-2007, 11:04 AM
Guys - this huge fat dude with a white beard and a goofy red suit invaded my house last night and left me a pair of Suzuki DL1000 Handguards from Ron Ayers - what a nice guy. He was actually acting on behalf of my wonderful wife.

Here's the deal -

Here's what you get for $50.
http://i195.photobucket.com/albums/z62/stearnsp/Parts.jpg

Here's the bike with no guards:
http://i195.photobucket.com/albums/z62/stearnsp/WithoutGuards.jpg

Here's the right guard - went on in 5 minutes completely stock:
http://i195.photobucket.com/albums/z62/stearnsp/StockRightGuard.jpg

Here's the left guard mounted per instructions and left stock - clearly not good and not meant for the 1250 Bandit.
http://i195.photobucket.com/albums/z62/stearnsp/StockLeftGuard.jpg

Here's the left guard after I modified it to mount much closer - stock version is for the DL series cable clutch not the GSF1250 hyrdraulic clutch. This took about an hour to get it modified via the Dremel tool and such. You need to watch tightening the hardware on the clutch side as is compresses the clutch lever and makes it stick and sluggish.
http://i195.photobucket.com/albums/z62/stearnsp/ModifiedLeftGuard.jpg

Here she is all guarded up. Test ride in 29 degree wind at mild speeds proved well worth the effort. These will be very nice in the rain as well if that ever happens.
http://i195.photobucket.com/albums/z62/stearnsp/WithGuards.jpg

From the driver seat - hands with or without gloves fit perfect. It does hit the fairing on full lock to lock - BUT - you can lock the handlebars and still have 1/2" to spare - so all is good.
http://i195.photobucket.com/albums/z62/stearnsp/WithGuardsfromRear.jpg

A1A
12-25-2007, 08:44 PM
Ok Phil, don't keep us guessing here. What did you Dremel and and such off to make the left guard fit?:giveup:
I'm also confused with the Hand Guards you purchased. The DL1000 has a hydraulic clutch actuation and the DL650 has a cable actuated clutch. So are you sure you didn't purchase the DL650 guards instead of the DL1000 guards? Also the hand guards are looking real good, great job well done.:clap:

:rider:

PhilS
12-25-2007, 09:14 PM
The guys at Ron Ayers said this was the only kit available. I chopped the left guard where marked on the photo. All in all and after the 20 miles test tide - I am totally happy. DL1000 kit was 57300-27820-291 which changed to the DL650 kit 57300-27821-291 which ended up being 57300-27822-291 which is what they had and sent. Here's how I modified the guard:

http://i195.photobucket.com/albums/z62/stearnsp/StockLeftGuardNotes.jpg

Ken Phenix
12-25-2007, 10:36 PM
Hey Phil,
Nice job on the guards!

A1A
12-26-2007, 08:46 AM
The guys at Ron Ayers said this was the only kit available. I chopped the left guard where marked on the photo. All in all and after the 20 miles test tide - I am totally happy. DL1000 kit was 57300-27820-291 which changed to the DL650 kit 57300-27821-291 which ended up being 57300-27822-291 which is what they had and sent. Here's how I modified the guard:

http://i195.photobucket.com/albums/z62/stearnsp/StockLeftGuardNotes.jpg

You did a good job Phil, looks like GSF1250 Hand Guards to me.:clap:

Thanks for sharing!

:rider:

treybrad
12-26-2007, 09:02 AM
Thanks for the detailed write up Phil. The same fat guy left me some as well. He also left a Manic Salamander throttle lock... I'm wondering if they will both work together though... We'll see, I'll install it this weekend..

trey

Brass
12-27-2007, 08:16 AM
Phil,

Do they both touch the fairing at full lock or is it just one of them that hits?

I have no clearance problems at all. I'll attach some pics once the camera batteries charge up.

To help them clear loosen your handle bar and rotate it back slightly (closer to the rider). Be careful to not turn it back too much or it will hit the tank at full lock. Once you have it set, re-adjust your levers by rotating them down until they are in a comfortable position again. That should help.

PhilS
12-27-2007, 08:32 AM
Phil,

Do they both touch the fairing at full lock or is it just one of them that hits?

I have no clearance problems at all. I'll attach some pics once the camera batteries charge up.

To help them clear loosen your handle bar and rotate it back slightly (closer to the rider). Be careful to not turn it back too much or it will hit the tank at full lock. Once you have it set, re-adjust your levers by rotating them down until they are in a comfortable position again. That should help.

They both touch lock to lock. I have the Daytona bars on mine which have less sweep or pullback than standard which accounts for why both touch on lock to lock. They only touch when I am parking or manuevering at feet down speeds into the garage. I can lock the handlebars and still have 1/2" clearance so all is good. I could rotate the bars as you suggested, but I love the feel of how it sits right now - but that would certainly fix it as you suggest.

Phil

Brass
12-27-2007, 10:34 AM
The bars look very much like stock in the pics. I never would have guessed you changed it.

It may be worth trying to rotate the bars. Depending on how they are bent, you may not notice much difference on your wrists/palms.

Here are pics of how they clear with the stock bars. I apologize for the dust on the bike. A hazard of parking it in the office for the winter is that to do anything to it requires that I be at work!

PhilS
12-27-2007, 10:39 AM
Spoke to Ron Ayers who spoke with Suzuki.......there's only one kit and it needs modified to fit the 1250 Bandit like I did. And there ya go.

With respect to the guards hitting, you and I might be experiencing 600 vs 1250 differences as well. I will be rotating slightly later this weekend.

Thanks for the insight.

A1A
12-27-2007, 11:12 AM
The GenMar up and back risers should keep the guards from hitting the fairing.

http://www.zianet.com/genmar

HTH's

:rider:

Brass
12-27-2007, 02:26 PM
With respect to the guards hitting, you and I might be experiencing 600 vs 1250 differences as well. I will be rotating slightly later this weekend.


I have the same DL650 kit as you, installed on my 1250. The only difference would be the handlebar.

Without rotating the bar, would it be possible to reposition (elongate) the mounting holes a bit more to gain the extra clearence you need?

PhilS
12-27-2007, 02:31 PM
OK - I got it. I thought you were speaking about comparing the 600 to the 1250. The bumping does not bother me, yet. I can elongate the holes to pull them in closer to the handlebar, but, I would be somewhat cautious as I would not want to see the unused elongated hole left after the adjustment.

If I do this, and whether it works or not, I'll post pictures.

Later - Phil

bones
12-27-2007, 04:26 PM
can any stromers attest to how these actually function if the bike goes down? I'd hate to put Mair barkbusters on a bike like this, but I like their function and easy on/off of the guard for the warm months and still have protection. They took a beating on my KLR several times. Not that I will be fire roading the Bandit. :rider:

Gilk51
12-27-2007, 05:05 PM
can any stromers attest to how these actually function if the bike goes down?

They won't help any on a go down - they are pretty flimsy for ground impact protection. I replaced mine this year due to a sand flop in April. I had them off the bike for a while and I will vouch for their usefullness as wind protection - that they do well. :thumb:

If you want impact protection, you need to go with the metal framed guards.

gunzip
01-31-2008, 10:24 PM
Unfortunatly I drop tested my hand guards last weekend ! A dog ran under me as I crept up the gravel road I live on to get to the blacktop.
The bike landed right on the handguard and turn signal on the right side , popped the turn signal in , slightly scratched the end case on the motor.
The hand guard survived with just a few pit marks from the gravel so I am impressed , the dog survived with a pit mark from the rock i beaned him with

Ken Phenix
02-01-2008, 01:41 AM
Unfortunatly I drop tested my hand guards last weekend ! A dog ran under me as I crept up the gravel road I live on to get to the blacktop.
The bike landed right on the handguard and turn signal on the right side , popped the turn signal in , slightly scratched the end case on the motor.
The hand guard survived with just a few pit marks from the gravel so I am impressed , the dog survived with a pit mark from the rock i beaned him with

Glad you and the hand guard held up ok. I was impressed when mine didn't break on my little get-off earlier this month in Waco.

http://www.twtex.com/forums/showthread.php?t=23978

sproggy
11-15-2008, 10:25 AM
Can any of you guys who've fitted the DL650 guards to a 1250 comment on what you used as a clutch pivot bolt? The stock one isn't long enough to go through the guard so I'm guessing you've used the one supplied in the kit for the cable clutch?

I'm concerned about doing this - the bolt supplied in the kit isn't right for the hydraulic clutch - it'll give the clutch lever only half the amount of bolt to pivot on (accelerating wear on the lever?) and also won't prevent the housing from 'closing up' and pinching the lever as the stock bolt does. Have any of you experienced these problems? I'm thinking that a modified version of the right hand pivot (as supplied in the kit) would be far better/safer. This should be available as a DL1000 spare part.

Any thoughts?

opflash
03-16-2009, 09:06 PM
I am interested in doing the same handguard mod to my 2000 600 bandit. I am wondering did you retain the stock bar ends or were those the bar ends from the vstrom? how does the handguard clip into the bar end? Also what exactly does that clutch sensor do? and clipping it will have no effects? thanks in advance

Ken Phenix
03-16-2009, 10:03 PM
I am interested in doing the same handguard mod to my 2000 600 bandit. I am wondering did you retain the stock bar ends or were those the bar ends from the vstrom? how does the handguard clip into the bar end? Also what exactly does that clutch sensor do? and clipping it will have no effects? thanks in advance

The kit comes complete with spacers that the guards clip on and longer bolts to go through your existing bar ends. The switch prevents the starter from engaging unless the clutch lever is pulled in. Without it the bike could start in gear if the kickstand is up. You can eliminate it by connecting the wires together. I wasn't comfortable with that so I removed the plug and trimmed the terminals on the switch and soldered the wires on directly. Then I painted the terminals with liquid electrical tape. The only other mod I recall was drilling a hole for the clutch cable to go through. I thought I'd take the handguards off in the summer but I just leave 'em on year round. If you ask me, they are well worth the effort.

opflash
03-16-2009, 10:49 PM
awesome thanks for the information. Is there anyway in your opinon on getting around cutting the clutch sesor wires. Meaning can you cut or modify in your opinion the handguards to avoid cutting the sensor wires. It wouldnt be that big of a deal just thinking about all the options

Ken Phenix
03-17-2009, 07:30 AM
awesome thanks for the information. Is there anyway in your opinon on getting around cutting the clutch sesor wires. Meaning can you cut or modify in your opinion the handguards to avoid cutting the sensor wires. It wouldnt be that big of a deal just thinking about all the options

I suppose you could just solder wires onto the trimmed switch terminals and crimp on some male spade terminals to plug into the bike's harness. Then the only thing you'd have to do to restore everything is buy another switch.

If you're ok with removing the switch altogether, just make a little jumper for the plug.

jdwinter001
01-22-2011, 10:08 PM
To revive this thread... Thanks Phil for the handy writeup and drawing of what material you removed. My installation isn't quite as clean as yours, but I'm very happy with it. Did a test ride in the 40's today and only needed my summer gloves (much better feel with those gloves, so I'm already happy with the mod)

BlueStreak
01-27-2011, 06:59 AM
Can any of you guys who've fitted the DL650 guards to a 1250 comment on what you used as a clutch pivot bolt? The stock one isn't long enough to go through the guard so I'm guessing you've used the one supplied in the kit for the cable clutch?

I'm concerned about doing this - the bolt supplied in the kit isn't right for the hydraulic clutch - it'll give the clutch lever only half the amount of bolt to pivot on (accelerating wear on the lever?) and also won't prevent the housing from 'closing up' and pinching the lever as the stock bolt does. Have any of you experienced these problems? I'm thinking that a modified version of the right hand pivot (as supplied in the kit) would be far better/safer. This should be available as a DL1000 spare part.

Any thoughts?

Can one of you that put these on a 1250 address sproggy's question? I'm wondering about this as well.

Thanks.

Ga-Bandit
01-27-2011, 09:40 AM
Can one of you that put these on a 1250 address sproggy's question? I'm wondering about this as well.

Thanks.

I put the DL kit on my bike w/o too many issues - I just trimmed the guards.

I don't remember if I used the supplied bolt or the existing one but I think the thread mounts to the perch in such a way you can make it work. I'll try to look this weekend and post again.

BlueStreak
01-27-2011, 05:56 PM
Thanks, Ga.

Sent from my Evo 4g on Sprint