I'm not really understanding your problem. Is your levers touching the guard? Can you post some pics. I fiddled around with some barkbusters and some answer handguards and they were too tight. I finally broke down and bought the ones that KLRFAQ advised to get. Maier woods pro.
94 KLR,tank guards,sw motech centerstand,Doo done, african switch,mirror dampners, powerpegz, twisted throttle fuses, aluminum skidplate, Bigcee shark disc and jug holder and subframe upgrade, progrip grips,maier handguards/brushguards, avon distanzias,fmf q4 exhaust, headlight guard, handlebar risers, billet rear brake reservoir bracket and guard, dual star shifter,garmin 2820 gps, tmod,disc cover, pcv mod,corbin flat