Trouble installing barkbusters handguards - 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 6 Old 05-19-2018, 03:28 AM Thread Starter
Join Date: May 2018
Posts: 6
Trouble installing barkbusters handguards

So I heard about this forum but never visited it until now, bought my first motorcycle ever last month (all black 2018 klr650) and I haven't had any trouble with any of the mods I bought for it except for the barkbusters. None of my friends have ever been into bikes and my family is deathly scared of them so I can't ask any of them for help. I got the STM-003 but they don't seem to fit quite right. Does anyone know of any videos that can help me or would anyone talk me through the process? Did I buy the wrong ones? I'm as new as they come to forums and bikes, any help will be much appreciated.
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post #2 of 6 Old 05-19-2018, 09:59 AM
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Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,454
Welcome and congrats on your new bike. I have Gen1 KLR's with aftermarket bars and Acerbis and Cycra handguards so I have no experience with the Barkbuster Storms on a Gen2 KLR but hopefully someone who has will chime in. That said I've installed dozens of handguards on various bikes and it isn't uncommon for them to require some "tweeking" to fit perfectly; a well mounted vice and a large crescent or the right size pce of pipe generally does the trick allowing you to modify the aluminum bar to fit your bar bend.

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post #3 of 6 Old 05-20-2018, 08:01 PM
2nd Gear
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Join Date: Aug 2017
Location: Kincardine, ON, Canada
Posts: 168
I have installed the BB Storm on my 2016; had I not gotten a great deal on them I would have sent them back and looked for something specifically designed for the KLR's handlebars.

On the left side you'll need to remove the metal hoop that is between the triple tree clamp and the switches because that's exactly where the BB clamp needs to go.

I also had to pivot my clutch and brake levers down further than I like to allow clearance for the brake line and clutch cable against the BB mounts. Doing so puts the protection of the BB aluminum bar above the clutch and brake levers which renders it useless in a fall or impact.

I'm sure they are a great product, but not for the KLR

A wish is a desire without an attempt
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post #4 of 6 Old 05-20-2018, 09:37 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,688
There are NO hand guards that are model specific! Other than what came on the bike.

One must make any and all of the aftermarket guards FIT any bike!

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #5 of 6 Old 05-21-2018, 12:33 PM
2nd Gear
Join Date: May 2011
Location: Clackamas OR
Posts: 100
I didn't install Barkbusters but had a similar issue with Tusk D-Flex...all installed now and love them.

Here is my over-worded "how to". It really was much easier than the wall of text in the thread:
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post #6 of 6 Old 05-21-2018, 07:11 PM Thread Starter
Join Date: May 2018
Posts: 6
Thanks for the input, after cutting off the metal hoop and grinding down the stubs I was able to fit them just fine. Also had to move the break line up a little on the right side so it wouldn't touch the bar.
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