Tusk D-Flex hand guards on Gen II KLR - tips? - 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 7 Old 03-13-2018, 09:01 AM Thread Starter
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Join Date: May 2011
Location: Clackamas OR
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Tusk D-Flex hand guards on Gen II KLR - tips?

I bought a set of Tusk D-Flex hand guards and went for the install last night. Ad I had learned with some interweb searches, the right side is pretty easy. Cannot use OEM or Tusk bolts due to the bars having welded in threads.

Actually, I was able to mount using the Tusk bolt and the bar end weight...and a fender washer.

Over to the left side. Looks like I need to cut off the welded on cable stay ring on the bar and blend flush. Also, the clutch lever hits on the Tusk bar.

Anyone have any tips or suggestions? I didn't finish the install last night but did get bunch of other stuff done: chain adjust/lube, oil filter clean/lube, torqued the header bolts (loose...), replaced the winter air with spring air in both tires...

Appreciate the input.
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post #2 of 7 Old 03-13-2018, 08:27 PM
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Location: Victoria, Australia
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Not a tip as such.
I had a similar issue fitting Bark busters. I had to cut & bend the cable stay ring & cut the ball off the end of the clutch lever & then round off the end of the lever a little to ensure it was still finger friendly.
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post #3 of 7 Old 03-14-2018, 09:37 AM Thread Starter
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Location: Clackamas OR
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Thanks much...I dove into this after work last night. Not a bad job and a Dremel made this a breeze.

For others as a guide:
Bar end weights and OEM guards removed...

Throttle side:
- Remove the ignition wire plastic strap...just pull it out, you will put it back later
- Install the inner swivel clamp for the aluminum bar...leave it loose
- Install the aluminum Tusk bar AND plastic. They are intertwined and need to be put together as a unit.
Note: the KLR has welded in bar end threads. You will need two new M8 1.25 x 35 Oval or Countersunk head bolts. The Tusk bolts (used with expanders) lack thread at the head. Or, you can install the bar end weights with the Tusk bolts and a fender washer...I bought two new bolts at Lowes.
- Install the inner bar end to the inner swivel. Now everything is connected.
- Start to snug everything up and position. Check full bar swing. May just contact wind screen.
- Like where it is? Lock it down.
- Put the plastic ignition wire strap back into place

Clutch side:
- Cut off the D shaped ring that has the enricher (choke) cable routed through
- Remove the horn/turn wire plastic strap...just pull it out, you will put it back later
- Blend the welds semi flush when you cut the D ring. I touched up with some flat lacquer
- Blend or cut off the end of the clutch lever. Blend smooth.

SAME AS ABOVE
Install the inner swivel clamp for the aluminum bar...leave it loose
- Install the aluminum Tusk bar AND plastic. They are intertwined and need to be put together as a unit.
Note: the KLR has welded in bar end threads. You will need two new M8 1.25 x 35 Oval or Countersunk head bolts. The Tusk bolts (used with expanders) lack thread at the head. Or, you can install the bar end weights with the Tusk bolts and a fender washer...I bought two new bolts at Lowes.
- Install the inner bar end to the inner swivel. Now everything is connected.
- Start to snug everything up and position. Check full bar swing.
- Like where it is? Lock it down.
- Put the plastic horn/turn wire strap back into place

- Then, if you bought the additional spoilers (larger wind protector), install with the provided screws. These sandwich over the first set of plastics. Or, just secure the first set.

Go ride.
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post #4 of 7 Old 05-02-2018, 06:32 AM
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Any chance you can post pics of the finished install?
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post #5 of 7 Old 05-02-2018, 09:07 AM Thread Starter
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Join Date: May 2011
Location: Clackamas OR
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My "how to" is a little long worded...main thing to remember, put everything on, line it up, THEN tighten it down.

I'm going back and forth with the bar end weights right now to see how much they help with vibs.

Some pics:
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post #6 of 7 Old 03-19-2019, 09:03 PM
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Location: Hallett Cove, South Australia
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Quote:
Originally Posted by outdoorgb View Post
My "how to" is a little long worded...main thing to remember, put everything on, line it up, THEN tighten it down.

I'm going back and forth with the bar end weights right now to see how much they help with vibs.

Some pics:
Nice! I'm trying to source smaller levers before I do my EGO BarkBusters fitting. Have come across smaller looking warp-9-levers but have emailed to find out lengths. I can't see the sizes anywhere.
The cut off clutch lever you did looks good. Do your fingers/hand slip off the end at all now the ball is no longer there?
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post #7 of 7 Old 03-20-2019, 10:08 AM
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Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,344
I've always been able to install my handguards without having to resort to lever surgery......takes a vice, hammer and a pipe sometimes.

Cheers,
Dave
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