Happy Trails bars and guard combo was not a simple bolt on ! - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 16 Old 10-19-2012, 11:57 PM Thread Starter
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Happy Trails bars and guard combo was not a simple bolt on !

8 hours later and another 35 bucks in stainless screws and spacers i finally got damn guards to fit around controls and switches .. still aint right but it works for now ..

i took em on off 50 times today trying to find the right combo to clear levers and cables ony to interfere with cross brace on bars .

ii ended up having to use spacers and longer bolts on bracket to clear master cyl and clutch adjuster ..

still dont really clear very well but i can ride it now ..
bars are nice stout protapers but the moose racing large guards and brackets suck ass for street bike klr ..

i also ended up braking the guide on choke cable trying to swing guard up as i was tighning the brackets

2000 army green klr
2012 blue/white /blacked out daily driver

recession is when your neighbor looses his job
depression is when you loose your job
recovery is when Obama looses his job

Last edited by Tom Schmitz; 10-26-2012 at 01:43 PM.
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post #2 of 16 Old 10-20-2012, 08:43 AM
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I had a frustrating time installing hand guards too. You would think that with so many KLR's made that some manufacturer would make a KLR specific bracket and guard.

I've heard the Acerbis guards are easier and fit good.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #3 of 16 Old 10-20-2012, 12:34 PM
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Quote:
Originally Posted by wayne_l View Post
8 hours later and another 35 bucks in stainless screws and spacers i finally got damn guards to fit around controls and switches .. still aint right but it works for now ..
I forgot the brand I bought, but I had to bend those puppies in a vice to get them where I wanted them. Zany.
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post #4 of 16 Old 10-21-2012, 12:31 AM Thread Starter
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they are just to short on the bar end side . If i had just another inch the levers would clear beautifully. on the other end i uses a 1/2 aluminum spacer to clear master cylinder and clutch adjuster and had to buy 35 bucks worth of longer stainless screws ..ill prolly swap them out once i finder a better fitting set .. im ticked .. these were labeled as klr fitting .. took me 2 days and a broke choke cable ..

2000 army green klr
2012 blue/white /blacked out daily driver

recession is when your neighbor looses his job
depression is when you loose your job
recovery is when Obama looses his job
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post #5 of 16 Old 10-21-2012, 10:49 AM
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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.

Lar.
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post #6 of 16 Old 10-21-2012, 11:49 AM
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Quote:
Originally Posted by biglar View Post
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.

Lar.
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.




Last edited by planalp; 10-21-2012 at 11:52 AM.
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post #7 of 16 Old 10-21-2012, 06:49 PM
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Planalp, I'm working on it but don't get the "Share" under the photo. Tried it in Library and same thing. I did get a line under "Image Links" that gives a line titled "EM and IM, but when I click on it it just copies to somewhere. On the welcome page is a line saying, "Share with Friends," but it leads nowhere.

Maybe we're using different versions ??
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post #8 of 16 Old 10-21-2012, 07:09 PM
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Well, I finally got it worked out and it won't let me post the URL to the picture cause I haven't posted to the forum 15 times.....and I think this is post 13.
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post #9 of 16 Old 10-21-2012, 07:11 PM
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Hmmm........let's run up a couple more posts here and see if we can beat this.

I looked on google for Tusk off-road hand protectors and it came up with several dealers and pictures. Might be an easier way to go.
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post #10 of 16 Old 10-21-2012, 07:16 PM
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It's really giving me a hard time with that 15 posts thing. Let's see if this gives me 15.
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