Motech Crash Bar Fitting - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 3 Old 07-29-2014, 10:15 PM Thread Starter
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steferf's Avatar
Join Date: Jun 2010
Location: Rolla, Mo
Posts: 576
Motech Crash Bar Fitting

I installed my left Motech crash bar about two years ago. I was never able to fit the right one on. I returned it to Twisted Throttle based on what the measurements should have been (we thought it was a manufacturing defect) and the new one also does not fit. I haven't dealt with it until now.

It is about half an inch off (see the first picture -- this is the closest I can get it). Anyone encounter this problem and solve it non-destructivly? I'd prefer not not bend or weld, as the powder coating on these falls off if you look at it the wrong way. I am thinking about fabbing a plate to extend the reach of the bar.

Any other ideas of what I could do?

Picture 1) Crashbar hole not aligning with subframe bolt axis (Eagle Mike drill through kit). This is as close as I can get it and I tried everything.
Picture 2) I didn't really need to include this picture, but it is everything I got goin on. Note, the board I have the bike propped on did not hinder the crash bar. Red ratchet strap is because I just did the eagle mike drill through mod.
Picture 3) My left crash bar installed no problem, therefore proving I am not completely insane....I sat there trying to get the right side on for at least two hours. That is in addition to the disassembling and reassembling and drill through mod. And then I took the entire shebang apart again when the new crash bar came. No dice.

2006 Red KLR 650

1)Doohickey Planned and purchased 2)Aftermarket Grips 3)Grip Heaters 4)Happy Trails Hard Luggage Rack 5)20 mm ammo cases planned soon 6)Aftermarket Exhaust 7)Thermobob 8)Happy Trails Fork Brace 9)Stainless Steel Oil Filter 10)Magnetic Drain Plug

See profile visitors post for details and planned mods.

Last edited by steferf; 07-29-2014 at 10:16 PM. Reason: typo
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post #2 of 3 Old 07-30-2014, 12:16 AM
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Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
You are lucky that you got the earlier style Motech, IME. The later one clamps around the lower frame tube with a "connecting rod cap" type connection. This makes the clamp protrude at least 1/2" below the frame tube which is really nice because there is the choice between cutting a section out of the engine crash plate and having the clamp as a 1/2" "catch point" for anything you slide over, or shimming the plate down at the back and reducing ground clearance.

The guards I've installed are really well finished and look stronger than many others but the fit....?

Just a heads up although I understand both types are discontinued.

I'm sure that you've considered but what about using a come-along to pull the rack into position? If memory serves, those racks are too strong to use the tip of an alignment bar placed through the rack hole and into the frame hole.

Don't know what bending facilities you have but an exhaust shop or electrical contractor may be able to help by bending the front back while holding upward on a padded pipe placed over the offending tube. Some wood screws and a couple of 4x4's should also get it done.

Wish you were closer.
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post #3 of 3 Old 07-30-2014, 01:47 PM
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Join Date: May 2014
Location: Texas
Posts: 1,260
I like your idea about fabricating a plate to extend the reach of the bar. It seems like the most fool proof approach. Secure the other two mounting points, make a plate, drill it to match the bolt, clamp the tab on the bar to the plate and weld in place. Perfect fit.

The bars can be tweaked some if no other choice is available. I took my left side bar off to get to the radiator fan which had come loose from its mounts in the Nevada desert on the TAT. Due to prior crash testing the bar was a little warped and wouldn't fit back on. I managed to force it with a ratchet strap and a phillips screwdriver as an alignment pin. It felt like a toss up as to which would bend first the KLR or the crash bar.
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