Case savers.... done...

[Eightmarky]

Ok, I'm interested but u make the installation sound complicated.  How long will they take to install?  Thanks.   :mrgreen:

[Kerry]

On each side: Remove 2 nuts, put case guard in place, retighten nuts.  5 minutes?

BUT!

It seems to me that the Suzuki guards came with an extra threaded rod.  You had to remove the longer OEM engine mounting rod and replace it with the one they sent, then replace the shorter OEM rod with the longer OEM one.  This was so there would be enough length to accomodate the extra thickness of the mounting tabs on the guards.

Moving the rods around doesn't add that much to the installation time.  But you should check with Srinath about whether an extra rod is needed, whether it's included in the price, etc.

One more thing.  To get the nuts off you will probably need two similarly-sized wrenches.  Unless one of the wrenches has a LONG handle (I used my torque wrench) you may need a second person.  If you can't get both nuts to turn, you may need to

* Pull the rod all the way out.
* Thread it through one guard and back through the engine block.
* Put the other guard on the protruding rod.
* Put the nut back on.
* Wait to tighten until you've done both rods.[/list:u]

[The Buddha]

The suzuki guards came with 2 bolts, one of which was too short, it was shorter than the damn stock one. I had measured it up and knew that it was short before davipu showed up at my door. So I took 3/8th stainless rod and tapped both ends of it with a 3/8 - 24 tpi tap, and forgot to get nylock nuts and asked him to get some on his way over. The stock bolts are the same that are used for the case savers, except they need to be longer. I will buy bolts that will fit these, Include instructions to get these on and send them out. The pieces are not harder to fit than suzuki's or anything like that, but instructions came with that lot as well. I also have some ideas on how they should go on. I have thicker end plates on them, and as such I'll like to have them outside the frame... They will fit inside as well, but that tight space might be bad to stuff them in there... cos in case they move in a crash... they might nick the cases or the frame. OH BTW the suzuki cases are the same way... OK it might not move enough in a crash... but I'd minimize the risk anyway. But its up to each person to fit it the way they want. They should also be spaced out for the projection you like... the wider it is, better protection, but more intrusive in cornering... if you are a serious cornerer... So get a stack of flat washers, some split washers and fiddle wiht it. Few minutes is all it took us on davipu's bike... and it was pouring rain then.
Cool.
Srinath.

[crash]

i'm  

i took a quick look, and i THOUGHT that the guards are put onto the rods that hold the engine block on/in the frame.

if that's the case, why do we need bolts?

[Kerry]

Rods, bolts ... same thing.

Now that I'm at home, I checked my original equipment.  The bike came with 3 engine mounting BOLTS (hex head on one end, short threaded section and washer and nut on the other).  It was my Five Stars engine guards that came with 3 (fully-)threaded rods and nuts/washers for each end.

Sorry for the mix-up.

[The Buddha]

I made threaded rods... Out of stainless 3/8 rod stock... damn near broke my hands... and chewed up 2 taps and ended up being a little crooked. I am buying bolts... 12 inch 3/8th dia hex head... You dont even want to know what they cost. OK OK they cost $2+ a piece. Box of 100 ~ $210. But anyway the case savers are done, and turned out quite nice if I may say so myself.
Cool.
Srinath.

[Kerry]

Srinath, now that you've confessed to both bending and threading skills, perhaps you would consider a quick "one off" job for seamax?

(See Mirror extenders/extensions..do they exists?.)

I'm not sure which would be the most appropriate grade of steel, or whether the rod would have to be heated before it was bent.

Darn!  He could have gotten 'em powder-coated, too!

[The Buddha]

I'll try... The rod has to be threaded cold, and any larger than 3/8 is going to be very very hard. Mild steel wont work well when you try this, cos the vice and the tap will chew up the metal... I'll do it with stainless steel. Or if you wanted to you can cut up 2 bolts and weld them at right angles.
Cool.
Srinath.

[Rema1000]

How about bending threaded rod, then doing something simple to cover/hide the threads.  Use your imagination: paint it with rubber "instant tool handle", or cover it with electrical shrink tubing, or use fiberglass & epoxy...

But I suppose that cutting the heads off 2 bolts and welding them together would give a nice tight angle, if that's what you want.

[The Buddha]

BTW for case savers for sale post... look in the for sale section.
Cool.
Srinath.

[seamax]

If you have a chin spoiler /belly pan it doesn't  seem like from the pics posted that the case savers would fit without some custom cutting.

Any ideas or suggestions?

[crash]

dislaimer: i know nothing

AFAIK, there's 4 rods holding the engine on the frame.  maybe the back 2 are the same distance apart as the front 2  :dunno:

[Kerry]

If you have a chin spoiler /belly pan it doesn't  seem like from the pics posted that the case savers would fit without some custom cutting.

That reminds me.

Back when Suzuki DID offer OEM belly pans and case guards, the descriptions for both mentioned that they couldn't be used together.  I'm not sure how definitively that applies to aftermarket stuff.

[The Buddha]

I dont see how a belly pan can be used with this case saver either. The back mounts are not same distance or depth as front... and if they were you still dont want to fit it there.... cos 1. It will hit your foot... 2. the case savers protect you when you're moving forward... if its at the back of the case... it will not prevent the case from hitting... The case is widest in front... so the front gets hurt the most. I'll include instructions to fit them in each package.
Cool.
Srinath.

[Keloran]

they are bars of metal that attach to the frame. They are mostly like what is in this auction except that srinath is changing them some (different steel etc)

They help prevent engine damage in the event of laying down your bike

Funny you should mention that particular auction. I'll let you know if the bars fit on my bike once they get here.  

-Kel

[The Buddha]

Kel... you tyring to fit in on a GS500??? Dont even try it... its not even close. The 450's had spine type frames with presumably 1 down tube that split into 2 probably just ahead of the motor.... the GS500's have to be flat if you placed it on the end plates. Look at pic I posted.
Cool.
Srinath.

[The Buddha]

OK bolts got picked up few mins ago... so the whole kit and kaboodle is ready to go. comes with 12 inch looooooong bolts 3/8 dia grade 8 and nylock nuts... You can just bolt and go, or heck buy some washers bolt and go. Took me and davipu 10 mins or so in pouring rain... Dont ask for pics on my bike... the pics I put up earlier are it... cos the bike is DOA. $50 and shipping for all.
Will I make more of these... most probably, but the changes are going to be...
1. Smaller diamater tubing... 1 inch OD now, next run 7/8th or 3/4.
2. Narrower end plates. 1 inch wide now 3/4 inch next run....
The advantages of 1 inch... highway pegs bolt right on. 3/4 inch... nope. But 1 inch is hard to make cos there is barely enough room in the under side...
Cool.
Srinath.

[davipu]

ok.  I'll try to come up this weekend to swap and bring bars back, I just have to figure out this carb problem.   do you still have any of the bars that aren't welded?

[The Buddha]

For the 01 style, I do have 6 that I haven't even cut up, so yes. Bent yes, the final miter cuts, no.
You want to swap out the case guards for the thicker wall ones and some real bolts instead of my hand made rod pieces... lemme know. We can do that too.
Cool.
Srinath.

[WAP]

the pics I put up earlier are it...

Can someone give me a link to this (these) pic(s)? Can't seem to find it. I refer to pics of Srinath's case savers installed.  :dunno: