Tusk D-Flex Pro Handguards donít fit... Rocky Mountain complaint! - Kawasaki KLR 650 Forum
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post #1 of 42 Old 11-22-2019, 03:35 PM Thread Starter
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Tusk D-Flex Pro Handguards donít fit... Rocky Mountain complaint!

First off, this is my first purchase with Rocky Mountain ATV/MC. I ordered the Tusk D-Flex Pro Hand-guards for my 2008 KLR 650, which was recommended by their website. My first test fit, I noticed that these will not work with the KLR handlebars. My first correspondence with customer service was to determine which of their handlebars were these hand-guards designed to fit. I thought no problem, easy fix... nope... after several days of emails and online chatting, they could not tell me and only said that they are universal. I know for a fact that these were designed to fit someones bar to come up with the design. So then I proceeded to request a refund, but I was told that since I installed them there was no refund. I corrected them as I did a test fit and not a full install, but they would not budge. I then was requested to send them pictures of the test fit to see if tech support could help. I sent the pictures showing that they would not work with the stock bars. I was again told that I would have to bend], fabricate cut to make them fit as they were "universal". I kept asking, then why are they listed to fit a KLR G2. I've been doing everything they have asked for 2 weeks and still I can not mount the hand-guards to my KLR G2. This is the worst customer service experience I have ever felt with. I now have to file a dispute with my credit card company over a refund that I should have received, as now it's my only option. I have no problem returning them, I just want my money back so I can buy some that do work on my KLR G2.
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-Travis
"All those who wander are not lost... whether I'm Flying, Jeep'n or riding my KLR."

Last edited by WingingIt74; 11-22-2019 at 03:49 PM.
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post #2 of 42 Old 11-22-2019, 06:05 PM
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All of these types of accessories are "Universal Fitment".
It is up to the 'mechanic' to make them work, as the manufacturers could not possibly afford to have even 6 different bends, much less 60 bends & lengths.
They wouldn't even be able to afford to test an assortment of guards onto the multitude of oem bike bars, much less other aftermarket brand bars to achieve an accurate fitment list.

There are some different combinations of middle brackets, from various companies that may allow adaptation without actual re-bending.
Look at Acerbis, Cycra, Moose, Bark-Buster brackets.

Did you use a rigid spacer or a stack of washers between the rubber mount of the weight and the flat guard? Many people discard or re-purpose the weights, as an extra long bolt will be easily sheared off or at least easily bent in a lay-down.

Be glad that you don't have to try to fit them for your living.
Sorry for your frustration.
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post #3 of 42 Old 11-23-2019, 04:03 AM
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Frustrating, when expectations of, "Plug 'N' Play," are crushed--when products received require some modifications (e.g., application of bench vise, sledge hammer, vise-grips, file, pry-bar, drill, etc.) for fitment. A gross manifestation, sometimes (and perhaps a distortion), of the expression, "Some assembly required."

Yet, such is the world, as pdwestman says above. And, as he says, more compatible (than Tusk) handguards are available.

Installed Tusk handguards (with spoilers!) on my Generation 1 without excessive trauma, as I recall. A KLRista (as in, "frugal one") attraction of those products was their low cost. A refund loses its magic if one must BEAT it out of the vendor. A big seller (like RM ATV/MC) isn't as sensitive to public relations as was the corner grocer in the village. The return policy, developed by an anonymous manager, and executed by an anonymous clerk, remains backed up by a phalanx of attorneys on retainer by the company.

Among your choices: EAT the handguards (maybe re-sell them), MODIFY the handguards to fit, or . . . like little David, with one smooth round stone, FLING the projectile (your grievance) toward Goliath (the vendor).

DISCLAIMER: I'm not unsympathetic to your angst, and wish the best outcome for your situation, a transaction you entered in good faith.
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ďYou better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, youíre gonna be dead.Ē "John Russell" (Paul Newman), Hombre
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post #4 of 42 Old 11-23-2019, 08:28 AM
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Looks great ..... i bought somes like that one's

Quote:
Originally Posted by WingingIt74 View Post
First off, this is my first purchase with Rocky Mountain ATV/MC. I ordered the Tusk D-Flex Pro Hand-guards for my 2008 KLR 650, which was recommended by their website. My first test fit, I noticed that these will not work with the KLR handlebars. My first correspondence with customer service was to determine which of their handlebars were these hand-guards designed to fit. I thought no problem, easy fix... nope... after several days of emails and online chatting, they could not tell me and only said that they are universal. I know for a fact that these were designed to fit someones bar to come up with the design. So then I proceeded to request a refund, but I was told that since I installed them there was no refund. I corrected them as I did a test fit and not a full install, but they would not budge. I then was requested to send them pictures of the test fit to see if tech support could help. I sent the pictures showing that they would not work with the stock bars. I was again told that I would have to bend], fabricate cut to make them fit as they were "universal". I kept asking, then why are they listed to fit a KLR G2. I've been doing everything they have asked for 2 weeks and still I can not mount the hand-guards to my KLR G2. This is the worst customer service experience I have ever felt with. I now have to file a dispute with my credit card company over a refund that I should have received, as now it's my only option. I have no problem returning them, I just want my money back so I can buy some that do work on my KLR G2.
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post #5 of 42 Old 11-23-2019, 03:01 PM Thread Starter
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The Pro versions seem to be the only one in question as the D-Flex standard ones seem to fit better from what I have been told. I own a Jeep and I'm use to making parts fit sometimes, however these weren't even in the same ball park. When I got a contacted them, I asked them to what bars to they fit, which they could only tell me they were "universal". As a former drafter, I know if I would of designed these, I would of picked a Tusk bar to design these from. I would of happily given them more money for a set of handlebars that these would of fit. Other then that, I had no problems with my order, it's the customer service that I received afterwards. Then they tell me that they are not returnable as they have been installed, to me that's horrible customer service, especially this being my first purchase with them.

On their website, when you type KLR Handguards, these are listed and they do not say "universal" fit.
https://www.rockymountainatvmc.com/p...o-handguards-p

-Travis
"All those who wander are not lost... whether I'm Flying, Jeep'n or riding my KLR."

Last edited by WingingIt74; 11-23-2019 at 03:12 PM.
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post #6 of 42 Old 11-28-2019, 08:49 AM
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I installed Bark Busters on my 2003 KLR many years ago. I recall they needed some effort with a vice and hammer to install.
Earlier this year, I installed the Tusk D-Flex Pro's on my DL650.
When I took them out of the bag, I thought there was no way they would fit, but it really wasn't as difficult to install as I expected.
I hope you have a solid table vice and a big rubber mallet...
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post #7 of 42 Old 11-28-2019, 09:50 AM
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I understand how you feel. However, what they said; there are far too many bikes and bar combinations for aftermarket bark busters to be designed to suit every one. I've had 41 motorcycles to date and I've installed handguards on most of them and they all took varying degrees of "tweeking" to fit properly. The KLR is worse because you have less space due to the switchgear and interference with the fairing/windshield.

To make them fit, I typically use a combination of a vice, large crescent wrench and a pipe - I bend the alloy guards and get as close as I can and then allow the bolts to suck it into the final position. I have much better luck with high quality handguards from Cycra, Acerbis, etc. than I do with cheaper ones from Maeir, Emgo and the like.....mostly due to the difference in the quality of the fasteners. As Paul said, it helps to have a few different mounting brackets to choose from (I've collected many over the years) which makes fitment a bit easier; Cycra has some good ones in different lengths - they are high quality and not cheap. https://cycra.com/product-category/p...guards/clamps/

lastly, I won't compromise bar, lever or handguard position to avoid interference with bodywork - minor contact at full lock, I typically live with - more than minor and I'd be modifying the fairing or windscreen.

Dave
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post #8 of 42 Old 01-05-2020, 07:37 PM
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"Fit" is a somewhat relative tetm.

It took me several trips to the local ACE Hardware to collect enough of the right size spacers, couplers and fittings to get a set of Dark Buster hand guards to "fit" on my otherwise stock 2009 KLR...and that also entailed liberal use of a BFH.

"Chet from Chattanooga"
2009 KLR, blue
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post #9 of 42 Old 01-05-2020, 09:45 PM
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I just snip off the ends, then the levers fit with much less drama.
Ball ends are intended to prevent hand or body punctures during an accident.
But with the bark-busters or whatever, the likelihood of that is essentially nil.

YMMV.
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post #10 of 42 Old 01-06-2020, 08:17 AM
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