Handguard Install

[twowheelnut]

Hand guards? What, hands too cold to hold the veggie quiche? Jesus ladies, don't forget to plug in your warmie vests! :haha:

 

[SilveradoSlick]

I have the '05 and have the same "issue" with the hex portion not seating and thus positioning the right handguard about 1/4" higher. Got the hardware from FJR Goodies and the two bolts are identical.

The difference seems to be in the brake levers. The shoulders of the original pivot bolts are different lengths. I don't have enough ride time in cold weather with the handguards to be able to say if one hand stays warmer than the other. It seems like the higher-riding handguard might be better in the rain.

 

[galactus]

I had the same issue with the bolt not fitting. I fixed it with a die and put more

threads on it so it seated all the way.

fits fine, now.

 

[skyway]

I had the same issue with the bolt not fitting.  I fixed it with a die and put morethreads on it so it seated all the way.

fits fine, now.   

So there it is, thread length not long enough, easy fix.

 

[Canadian FJR]

Installed the guards on my '03 a couple of months ago and no problems. I simply followed Dale's instructions and installed in 15 minutes. All parts were ordered from a Suzuki dealer in Nova Scotia.

Canadian FJR

 

[madmike2]

Skyway, not thread length, but shoulder length. Cutting more threads will remove some of the shoulder and allow the hex portion to seat properly. I doubt the extra length of threads protruding from the bottom of the handle pivot will be a problem.

One question, did you guys try installing the pivot bolts "reversed", IOW, left for right and vice versa. I think I've reversed mine once and it made a difference.

 

[skyway]

Skyway, not thread length, but shoulder length.  Cutting more threads will remove some of the shoulder and allow the hex portion to seat properly. I doubt the extra length of threads protruding from the bottom of the handle pivot will be a problem.
One question, did you guys try installing the pivot bolts "reversed", IOW, left for right and vice versa.  I think I've reversed mine once and it made a difference.

Madmike2 - to be honest I did notice it was sticking up during install, but did zero investigation as it was late in the evening prior to an early morning departure for SoCal. I will check it out when the bike returns.

 

[FJRJeff]

One question, did you guys try installing the pivot bolts "reversed", IOW, left for right and vice versa. I think I've reversed mine once and it made a difference.

Both of mine are identical, I believe. I'm not near the bike at the moment, but both were the same part number.

Jeff

 

[radman]

One question, did you guys try installing the pivot bolts "reversed", IOW, left for right and vice versa. I think I've reversed mine once and it made a difference.
Both of mine are identical, I believe. I'm not near the bike at the moment, but both were the same part number.

Jeff

Ditto. The ones on WC's site are 2 of the same number, so swapping will make no difference. Cutting threads up the shank would.

 

[user 711]

The Internet parts guy at Suzuki Oneida sez if the lever bolt part numbers are the same, then they are the same lengh for all years 2002-2005.

Looks like I'll need to cut more threads on my bolt.

 

[radman]

Thats just it dan, they shouldn't be. There is a better fit for that right side, we just gotta figure out which part number it is.

 

[torch]

Hand guards? What, hands too cold to hold the veggie quiche? Jesus ladies, don't forget to plug in your warmie vests! :haha:

... he says from the frigid air of Santa Barbara, California.

Sorry TWN, I'm a wimp and I freely admit it. I do have a heated vest and I'm not afraid to use it.

I put the hand guards on shortly after this ride home:

 

[twowheelnut]

Well, it was a chilly 59 degrees this am when I left the house... May hit 85 today. Man, I hate the heat this bike throws out! :angry:

 

[radman]

Hope it chars yer nuts, ya basshat!! Oh, and I've seen all the TV disaster flicks. You're gonna get yours pally, yup.

 

[MCRIDER007]

I have the '05 and have the same "issue" with the hex portion not seating and thus positioning the right handguard about 1/4" higher.  Got the hardware from FJR Goodies and the two bolts are identical. 
The difference seems to be in the brake levers. 

I also got my hardware from FJR Goodies and the two bolts are identical. The problem is that the thickness of the portions of the clutch and brake levers that the bolts pass through are different, the brake lever being about 1/4 inch thinner than the clutch lever. The only way to make the bolt seat on the right side is to cut away the bolt's shoulder and extend the threads -- and then you may have to cut away the tip of the threads so the bolt does not hit the throttle cables.

I don't think anyone is going to have much success in finding the "right" Suzuki part since both my 2004 DL1000 and my 2005 DL650 have "thick" brake levers and would use the same bolt I already have.

 

[user 711]

Thats just it dan, they shouldn't be.  There is a better fit for that right side, we just gotta figure out which part number it is.

Well the part # for the screw is 57431-06G00 on FJRTech. There is another part # for the clutch side specifically for 2004-05, shown here:

#11 2002-03 57431-06G00

#11 2004-05 57431-06G10

It'd be interesting to see if the 57431-06G10 part might possibly fit, but I don't think I want to spend $18 to find out.

 

[twowheelnut]

Hope it chars yer nuts, ...

Well, tis the season for roasting nuts...

 

[MCRIDER007]

Thats just it dan, they shouldn't be.  There is a better fit for that right side, we just gotta figure out which part number it is.

Well the part # for the screw is 57431-06G00 on FJRTech. There is another part # for the clutch side specifically for 2004-05, shown here:

#11 2002-03 57431-06G00

#11 2004-05 57431-06G10

It'd be interesting to see if the 57431-06G10 part might possibly fit, but I don't think I want to spend $18 to find out.

I don't think that part will do you any good. My 2004 DL1000 has a different bolt on the clutch lever but the hex part of that bolt is about 1/4 inch longer than the hex part on the bolt for the brake side (which is the same bolt I have for the FJR). Can't figure out why, but the net result is that the clutch bolt would make the hex part even higher on the brake side.

 

[Warchild]

Jeeze, guys...... :blink:

Okay, everyone just ease back on the throttle,and lemme see if FJRGoodies will buy one 57431-06G00 bolt and one 57431-06G10 bolt, and I'll try them out on my 2003, and Ignacio's 2005 ABS, and we'll figger this crap out!

 

[toophast]

I have an 05 and thought I had missed something in the instructions. I installed the original handguard farkle in the fall of 04. Had a heck of a time getting the right side to fit correctly so I "jimmy rigged" it with 4 washers under the head of the Suzuki bolt to get things to line up correctly....

I'm going to be upgrading to the newer handguards because I'm now noticing "stress fractures" and splits in the plastic of the handguards where it is being compressed by the bolts/nuts. Oh, the trials and tribulations of a backyard farkler :bigeyes: