SW-Motech crash guards install - 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 5 Old 01-19-2016, 03:29 PM Thread Starter
2nd Gear
Join Date: Jan 2016
Posts: 335
SW-Motech crash guards install

Hey, I just installed these on my 15' and just wanted to give some input on how it went. First, I would recommend getting a 8mm hex bit to be used with a socket for the subframe bolts. The plastics were pretty easy to get off as was the skidplate. Watch out on the seat as there are two washers that may or may not fall when unbolting. The gas tank has to be propped up to gain access to the frame bolts. Remember to disconnect your fuel line and catch the gas that is going to spill everywhere when the hose drops.
Ok, now ya gotta unbolt the tank after the tank plastics. I will warn you, the right one kinda went in almost stripped from the factory and will be tough to unscrew as the threads show the wear. This is also evident as the right tank mount hole doesn't line up perfectly with the frame. Don't panic, later on when you button everything back up, I used a rubber mallet to tap on the tank mounting tab, pushing it forward for the screw to align and all was good. I used a ball of bubble wrap to prop the tank.
Now onto the front engine bolts. Expect these to move and not align once you pull the bolts out. My bottom one of the two was off. I wasn't able to tap the new bolts in but was able to use a socket and they screwed through the misalignment just fine.
The subframe bolts are going to take a little pressure to break loose. You will hear a horrific "snap" as they loosen and then they come out like butter, almost too loose. I did the left side first, and neither subframe moved a bit.
Pay attention to the order of the washers and spacers, and put blue loctite on everything. As for the rubber stickers that go onto the bars that mount to the lower frame, I didn't worry about shaving the little extra amount that may have stuck past flush. They bolted up fine.
So to sum up, it was about 3 hours and that included going to buy a 8mm hex. The bars are super high quality and look great. You may notice the left bars are closer to the fairing than the right, however, that side fairing sticks out an inch or so more due to the radiator. Just be careful of that gas tank bolt or you will strip it. Also be careful of the bottom front engine mount or you will damage the threads of the new bolt. Again I started with the left subframe bolt and was careful not to move the bike. You don't want those holes to move.
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post #2 of 5 Old 01-20-2016, 12:04 AM
1st Gear
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Join Date: Oct 2014
Location: Idaho
Posts: 93
No pics of at least the finished product? Go post a few bogus posts to get up to 15 to post a pic! hahah

2014 Green/Black KLR650 "New Edition"
2006 Yamaha Cherry Red FZ1
2007 Yamaha VStar 1100 (Wifes, but I've ridden it more than her)

Last edited by ReadyToBugout; 01-20-2016 at 02:49 AM.
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post #3 of 5 Old 02-15-2016, 02:07 PM
1st Gear
Join Date: Dec 2015
Location: Harrisburg NC
Posts: 80
I stuck a set on our KLR's in December, following the destructions it was pretty straight forward, pleased with the quality and outcome. Did the Dirt Racks on the rear ...
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post #4 of 5 Old 04-03-2016, 12:28 AM
Join Date: Apr 2016
Location: Cascadia
Posts: 2
I just got a used 2015 and put the Motech crash bars on it last night. I've been looking all over for information about why the right side is further away from the fairing than the left. I thought maybe I'd gotten the spacers in wrong or something so glad to hear it matches your experience as well. Actually just shot an email off to the company asking if it was intentional.

Be interested in a pic to see if your offsets are the same. I can't share an image for another, er, 14 posts.
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post #5 of 5 Old 04-03-2016, 06:12 AM Thread Starter
2nd Gear
Join Date: Jan 2016
Posts: 335
Yup. Not just you. I've seen plenty like that in pictures or YouTube (After I installed mine). They still give great coverage on both sides. It's just the radiator side seems to be 3/4" closer to the fairing then the other. But again that fairing sticks out more.

Last edited by Back2Kawi; 04-03-2016 at 06:18 AM.
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