Just wondering if anyone has had experiences in fitting one of these aluminum guards.

In my case, I've fitted it, but was a very tight fit. Part of the guard digs into the brake line too much for my liking. I've since filed a groove in that area, which is a lil improvement.

Any thoughts and suggestions?

Pic to come later.

Here is a pic of the aforementioned caliper guard...

I've always wondered why a guard like this is necessary; seems like the caliper is in a very protected area of the bike.
Anyone ever damage a rear caliper, and if so, how?

Which year and model do you have??

Are all hoses routed in that direction?

Here's another pic, showing the original guard in place. This was taken some time ago. But I can't help but ask... does the brake line look to be correct? Does everything look right in the picture? Now I can't help but thinking 'perhaps' the brake line is for a different bike... Oh and by the way, this is a 1996 model (H2).

I wouldn't want that wearing on the line. Why not take a file and remove a bit more metal from the guard until the brake line passes through cleanly?

As for damage, I'm glad I have one of these guards on my caliper. I ride in a lot of rock infested areas and the guard has certainly saved my caliper on more than one occasion

How does a rock large enough to put a caliper out of commission get up on TOP of the swingarm to even contact the caliper???
(Unless, of course, you are crashing...in which case I would think your rear caliper might be the least of your worries...)

my brake line looks the same I have a 97-98 kdx200

Mudpack rocks come in all shapes and sizes and sometime you'll end up passing through a crevis on the bald face of a mountian and notice a boudler will be sticking out at the top more than the bottom, and perhaps you have a mild get off around these boulders, the guard might be the difference between getting of the mountain with front and back brakes or just front brakes.. I have a plastic one and just hope for the best..

Is that actually touching the brake line? If it is, I'd be getting it off in a hurry.

I do think the caliper and or brake line was from a different bike. From my stock caliper the line came out and turned down toward the swingarm. I buggered up my caliper though, and am using one from a yz250. The line angles up like yours in the pic. I could not fit the stock guard for the same reason you're having a problem with yours.