My new-to-me 2011 came with the Tusk Off-Road guards on what I believe are stock bars. Looks to me like a perfect fit and no marks from bending or whatever. I uploaded a photo of one to Photobucket but don't see an option to insert it here.
biglar, I'd be interested in seeing the photo.
On Photobucket, click "Share" under the photo, and when the box pops up, select "Get Link Code." Put a checkmark in the box by "IMG for bulletin boards and forums." Check the "full size" box. Left-click and drag your mouse to highlight the link in the box. Right-click on the blue-highlighted text/link and select "copy" when the box pops up.
When you're back on the KLR forum page, left-click the yellow icon in the menu bar that looks like a mountain. Right click on the highlighted URL and another box will pop up. Choose "Paste." The photo should then show up in your post.
I open my browser twice and keep one on the KLR forum and the other on Photobucket. That way, you can keep your KLR forum reply open to edit while you fiddle around with the Photobucket.
I've been exploring options for some metal guards that would protect my levers but I would like to keep/alter the big stock hand guards and bolt them to the metal guards because I really like the stock plastic guards. The stock guards are very effective at keeping your hands warm and dry, but don't offer any effective protection for tipovers/crashes. I've been trying to examine guards that others have installed.
So far I've put this project off because I've done aftermarket guards on my other two DS bikes and it really sucked due to the problems you described.