Super Tenere 1200: Hwy Peg Mounts & O2 Sensor, Water Pump & Header Protection (utilizing Altrider crash bars & skid plate)

By Mike Mulligan June 28, 2017

1/8" 6061 aluminum stock $20 (Metal Supermarkets), no specialty tools used, jig saw, hand drill, flat & round metal file, wet/dry cloth sand paper, work bench drawer & counter used for bending jig, one 4" x 1" galvanized right angle bracket, two 1" x 5/8" right angle brackets with custom bend (dbled together for added strength), stainless button head hardware w/nylock nuts, used folding hwy pegs ($25 craigslist) & Dominion Sure Seal EZ Liner Black Bedliner & Industrial Strength Coating (attempt to match the Rhino coated skid pate & add scuff resistance). Several hours of R & D to finalize design & fitment. Of course none of this would have been necessary if I had a RideOnAdv or ACD skid plate because of their high side design that offers additional protection & mounting points for the pegs, but necessity is the mother of invention or so they say. Peg location is approx same height as the rider pegs of approx 14.5" & 16.5" forward, necessary to clear the O2 sensor with the peg bolt on the right side....too much further forward would cause clearance issues with the lower edge of the right side panel & shins, at least for me at 6' 1" w/33" inseam & low seat height. The Arrow header O2 sensor location protrudes outward slightly more than with the oem header. I used large thick washers on both sides of the plates when mounting the pegs for added rigidity/integrity because of the softness of the aluminum. I considered using the next thicker material but was concerned about ease of cutting & bending. A side benefit of this set up may be added rigidity to the skid plate from bottom hits because the loading is now transferred to the crash bar mounts as well. Pics are full size so can be zoomed in. Hopefully the grid paper will permit easy copying or at least provide approx measurements...I started with file folders for ease designing templates, then moved on to press board for rigidity to test fitment, then to aluminum. Investment in project: more hours than I care to admit, total cost approx $55 + a bottle of rum & my wife wondering why I spend so much time tinkering vs riding the stupid thing:)

Right Mount: Because the right crash bar mount is located about 1" further out than the side of the skid plate & the water pump protrudes about 3/4" from the skid plate, I opted to shape the mounting plate with 2 bends to clear the water pump then curve in & sit flush with the side of the skid plate. The challenge with the dble bends was ensuring the peg mounting hole was aligned perpendicular so the peg was oriented the same as the rider peg & further complicated because the lower bend is angled to match the skid plate side shape vs the upper bend. I added 1/8" spacers between the crash bar mount & mounting tab to provide adequate clearance & a little crush zone between the plate & the water pump. I may add a rubber pad to the inside of the right plate opposite the water pump housing to cushion any contact in a fall over. The Altrider crash guard bolts were long enough to accommodate the added thickness of the plates & spacers. I was able to utilize existing holes in the sides of the skid plate on both sides. The oem engine case bolt seems long enough to accommodate the thickness of the angle bracket on the left side. I added 1" diameter/wide vent slots to the mounting plates to increase air flow & mimic the look of the RideOnAdv skid plate. It was particularly beneficial on the right side with the heat radiated by the header & water pump.