Installation of VStrom Handguards on 2001 SV650

My wife rides an SV650 for Sport Touring. She used to complain that her hands would get cold so I've installed the "Knuckle Guards" from the early VStrom DL1000 model on her bike. The improvement in hand protection from cold air is dramatic and when combined with electric grip heaters from Dual Star, she rarely has cold hands now. If you're willing to replace the bar-end weights too, the newer DL650 knuckle guard "kit" appears to be pretty much a bolt-on deal. But because we wanted to retain her bar-end mirrors (and because we did this before those were available) that wasn't an option.  

The brake side installation was a simple trim and bolt up operation

However, because the VStrom uses a hydraulic clutch and the SV doesn't the clutch side mounting ends up being a "hack" The plastic requires quite a bit of trimming and the VStrom mounting bolt won't work. 

Installation

First of all, let's take a look at the lever mounting hardware

The left two bolts are the standard clutch and brake  lever mounting bolts on the SV. The long bolt on the right is the standard VStrom mounting bolt (both sides). The VStrom bolt and nut are item 5 and 6 below. You're going to need only one of these for use on the brake side. See below for the clutch side mount..

Note: Part numbers and prices are from the MR Motorcycles web site (http://www.mrcycles.com/

Parts

5 BOLT 57431-06G00 1 $12.11
6 NUT  08316-10063   1 $1.28

 

The VStrom (DL-1000) Knuckle Guards are as follows:

Parts

1-1 COVER, KNUCKLE RH (BLACK) 57341-06G00-019 1 $20.32
1-2 COVER, KNUCKLE RH (BLACK) 57341-27G00-291 1 $13.95
2-1 COVER, KNUCKLE LH (BLACK) 57541-06G00-019 1 $20.32
2-2 COVER, KNUCKLE LH (BLACK) 57541-06G10-291 1 $13.95
3-1 SCREW                                            02142-06107          2 $1.24
3-2 SCREW                                            09125-06118          2 $1.48
4    WASHER                                          09160-06130          4 $1.12
5    NUT                                                  08319-21068           2 $0.80

I'm not sure why there are two variants on the knuckle guards but I remember mine costing about $14 each so I'm thinking it's the "-2" variation.

 

Brake Side

Except for some minor trimming on the plastic hand guard, the brake side mounts up with the standard VStrom hardware.


That's the VStrom lever bolt in there - it works fine.

Lower view of brake side

Clutch Side

Okay, here's where you have to get creative. You probably won't need the extra set of holes for the cable tie. I missed the first time ;-)

First of all the VStrom bolt itself is too long. Refer back to the photo of the lever bolts above. The length of the "bearing" surface is much shorter on the mechanical clutch. I happened to have a spare KLR650 clutch side mounting bolt that worked perfectly. That's item 92002 on the diagram below. Kawasaki part number: 92002-1880. The nut is: 92015-1191 but I think the standard Suzuki nut will work too. You'll need one of these for the clutch side.

The KLR650 bolt worked but, it was still necessary to offset the handguard to clear the lever. This is just a short piece of aluminum with two holes drilled in it.

 

The bottom mount is the tried and true method of a black cable tie. It's not the most high tech approach but it works. Obviously servicing the clutch cable will require new cable ties but hey, that doesn't happen very often.

 

Good Luck and Enjoy!