Crash bar not matching mounting points

Questions regarding the DR800

Crash bar not matching mounting points

Postby Yuza » Sun Jan 07, 2018 5:35 pm

Hi all, when I bought the bike (sr42) the seller gave me a set of crash bars he removed from the bike since one of joint was broken.
I had it rewelded and I am trying to fit it, but
A) both sides touch the tank and
B) there is quite a big gap to the mounting points on the frame, particularly on the left side (the broken part was on the right so it shouldn’t be a bad alignment during welding the cause)
Any advice? Is there anything missing?
Thx
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Re: Crash bar not matching mounting points

Postby Mick75 » Sun Jan 07, 2018 6:51 pm

Have you got the spacer pieces at the front where the bars bolt to the down tube fitted correctly?
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Re: Crash bar not matching mounting points

Postby Yuza » Sun Jan 07, 2018 8:03 pm

I just have the bars screwed to the metal brackets on the down tube, no spacers at all.
But even with spacers the crash bar would move forward, not away from tanks, and bolts on the rear of the frame would be misaligned, wouldn’t they?
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Re: Crash bar not matching mounting points

Postby BigBob » Sun Jan 07, 2018 10:38 pm

From memory the two spacers at the front are 20mm long. Make sure you bolt onto the top front hole not the bottom one.
From memory the long bolt you will need is 130mm, but I`m sure you can measure it yourself.
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Re: Crash bar not matching mounting points

Postby Yuza » Mon Jan 08, 2018 8:37 am

I will make a picture of the front side, but I have just realized that my bike has 2 horizontal brackets welded to down tube of the frame which are not standard I assume...
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Re: Crash bar not matching mounting points

Postby Mick75 » Mon Jan 08, 2018 6:32 pm

Have a look at the RDMoto web site, there's some good pictures of all the parts and how they should be fitted
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Re: Crash bar not matching mounting points

Postby Yuza » Mon Jan 08, 2018 8:53 pm

Pics
Bolts not tightened, just by hand to see how it looks like
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Re: Crash bar not matching mounting points

Postby BigBob » Mon Jan 08, 2018 10:05 pm

Aaah! That explains the problem. Normally those crash bars use a couple of U clamps.
Not sure how well those welds would stand up to a crash.
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Re: Crash bar not matching mounting points

Postby Yuza » Tue Jan 09, 2018 6:20 am

And the U clamps would stand it better?
Might consider grinding the brackets off...
Or I’ll need to bend something here and there to make it fit
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Re: Crash bar not matching mounting points

Postby dave#22 » Tue Jan 09, 2018 10:57 am

I would have thought the obvious thing to do, would be to set the bars to clear the tanks, and make spacers and an additional wider bolt on plate to spread the bars at the downtube....or modify the bars to fit the existing mounting points.
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