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crash bars.

7K views 34 replies 11 participants last post by  foo 
#1 ·
Hi . Can anyone tell.me who makes crash bars that fit with the oversize tank.
 
#5 ·
Ok well not a very welcoming response. Thank you.im not new to motorcycles have been riding for 18 yrs. Currently own a ducati and a triumph. I will try not to be a smart ass. I received the bike for free with a ims plastic tank that was road rash on both sides and leaking from 4 places So I take that as a sign that this tank needs protection be cause i plan on riding it hard.. maybe if you don't have any information in reference to my question you should not say anything . Thanks.
 
#6 ·
Over the years IMS has made several different tanks for the KLR, and those which I am aware of are:
* Stock size that still used the OEM fan shrouds (fit Gen-1 and have been discontinued).
* Large size, typically ~7 gallons US (two variants, early had no slots, later ver had vent slots).
* XL Size, in black and natural/white, and holding about 10 gallons US.

Which version in on your KLR?
 
#9 ·
Sorry . Maybe I just took it the wrong way. I know if you ride off road eventually your going to fall. . And from the looks of the tank that was on this bike ( ims oversized tank) it didn't fair very well. So if I'm 800 mills away from home and for some reason fall and Jack up my tank I'm stuck. So if all I have to do is put some crash bars on it to avoid that and ride in confidence with the bars then thats what I'm going to try to do. I also have been on google all week trying to find info about bars that fit with the oversized tank. And can only find that all don't fit with the big tank.
So far I'm not feeling very welcome here .I have built a suzuki samurai for rock crawling and on other off road forums when you ask a simple question no one really cames one with smart remarks . I just looking for info from someone that has maybe been where I am right now looking for bars that fit with the big tank. I apologize if I have come off in a wrong way.
 
#10 ·
Freeklr650, Have you tried using the Google search On This Forum? So it primarily searches This Forum?
https://www.klrforum.com/gtsearch.php?q=IMS 6.6 & crash bars

I think that I might have read that the Dirt Racks brand might fit around the IMS 6.6-7 gallon fuel tank, on this forum with-in the last few of years.

And alas, Damocles responses can rub many people the wrong way. I've been on the receiving end. Yet sometimes he can be quite helpful. Just gotta' learn to separate the chaff from the good intel.

If you had been more specific about model year or Gen of bike and which IMS fuel tank it may have reduced his temptation, possibly.
 
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#14 · (Edited)
And alas, Damocles responses can rub many people the wrong way.
Oh? OH?????????

:)

I must say, I beg for a THOUSAND PARDONS, if mentioning the concept, IMS tanks serve in lieu of crash bars, offended anyone!

I take it all back. Don't know where I obtained such a foolish, absurd idea. I get it now; the tank protects the radiator; then, the crash bars protect the tank!

Forgive me, all, if you can find forgiveness in your hearts.

Good thing Peter somehow muddled through his projected 50,000-mile, two-year ride through the Americas with no crash bars and an unprotected IMS tank. (Kamikaze cab driver along the Mexico-Belize border creamed him; broke his leg; but the IMS tank protected his bike. Completed his ride, just as soon as his leg healed. DISCLAIMER: Anecdote only, from which no general conclusions should be drawn.)

https://s3.amazonaws.com/advrider-p...ges/N/NVTrailRider_0409140955_zps67f8bdeb.jpg

("I've never faked a sarcasm!")
 
#11 ·
I test fitted my older 7 gal IMS tank with the DirtRacks and with a bit of tweeking they would work.

No worries Freeklr - sometimes the tone and tenor of chatting don't come across correctly in text-based forums. You asked a simple question and offered an apology if it came across inappropriately. You are welcome here for sure.

Now let me see if I can find a few pics from test fitting the old black IMS tank ...
 
#15 ·
Damocles.... I'm drawing from what I have in front of me . the tank that was on this first gen bike I'm sure by the way it looks has taken more than one bad spill but is like I said leaking in 4 places. So . If all I have to do is put bars on it to never have to be worried about it then thats what I'm going to do. I'm not saying that this tank is going to fail with one simple fall. Are you a top secret representative for Ims and I have offended you because I want to protect this great tank with some beefy crash bars . Jokes.
 
#16 ·
Interesting thread. FWIW, I've seen people with Dirtracks and SW Motek bars on Gen1's with the IMS 6.6. I don't know how much (if any) tweeking was required to make them work. Personally, my riding is "offroad centric" and I use just the IMS tank and JNS radguard for protection and haven't had any issues despite a half dozen crashes, nor do I expect any. I raced offroad for 30 years and every offroad bike I had used a plastic tank, either stock, IMS or Clark and I've never had an issue depite literally hundreds of crashes. ....I removed the crash bars from my 2001 as I didn't want the extra 10-15 lbs and the bike is heavy enough as it is. All that said, I'm sure that crashbars add additional protection to the tank - I'm just not convinced it's needed or worth the weight penalty. YMMV

2 cents,
Dave
 
#17 ·
If it is leaking in four places my concern would be more along the lines of fixing the leaks.

Where are the leaks?
 
#19 ·
OK, makes sense.

I have had the IMS 10 and the IMS 6.6, both on the same bike. Both of them have been down a number of times and have served well to protect the bendy bits on the bike. The IMS 10 had a strut that served to help the left wing protect the radiator. Some have left that part out with poor results.

On the IMS 6.6 I think that a proper radiator guard will add as much insurance as is really needed. JNS make a very good one. Between that and the IMS tank you should be well protected. That said, there are bars that will fit. The problem is that so few put bars on with the IMS that information is a bit hard to find regarding what bars fit with the tank and with any given skid plate. Also hard to find is what might be involved in getting the tank off for service.
 
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#20 ·
IMS tank

I have an 06 with the 6.6/6.1? IMS tank that came on this bike used. I have researched bars and even have a set(not installed) and thought I would mod my bars but would be way wide IMO. I made sure tank was secure and went riding. I push(drills/training)my self on bike and my wife learned to ride on it,it's been down. Tank protects radiator just fine(never a thought now) and with hand control guards and happy trail pannier racks(small soft panniers) bike is all around well protected. Hope this helps.
 
#23 ·
I have a set of the Dirt Tracks crash bars coming for my Gen 2 with 7 gal IMS tank. I bought these based on another forum member's recommendation.

I'm installing the bars for two reasons, to protect the tank and to be able to be able to mount some highway pegs and aux lights. As strong as the tank my be, I don't want to take a chance of damaging it when I'm riding in such places like Baja where options for assistance are few. On the highway pegs, I've installed the adventure style pegs on three different bikes, BMW 1150GS, VStrom DL1000 and DL650. I find them to be a good place to stretch my legs when my knees/legs start to cramp. I learned the same lesson when on my first off pavement ride on my KLR. And of course there is no need to explain the desire for better lighting.

I'll post some pics when I get them installed with explanation of adjustments needed, if any, to mount the bars.
 
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#24 · (Edited)
Dirtracks bars will fit with the 10gal ims tank, but that style of mounting (lower subframe) makes it impossible to use a kickstarter. Also the happy trails highway pegs will not fit without modification if you have those bars.
6.6gal should fit any style of bars though. It's thinner than the big one.

Seriously, am I the only person who thinks it's dumb to have a gas tank as the primary crash/drop protection on what's essentially an oversized dirtbike? Everyone's up in here acting like it's a stupid idea to have bars with an ims tank.

And what's up with the smugness in here? It took FIVE people before someone came in and told the guy his answer. It would have easier and faster to just type "dirtracks." No wonder I can never find a riding partner, they're all on here bashing newbies for not knowing every single thing about the bike.
 
#25 ·
I don't think you're the only person, but you are in the minority! ;-) ......The KLR is essentially an oversized dirtbike....and almost every dirtbike I've owned has had a plastic tank and no crashbars. I've ridden and raced offroad for more than 40 years and I've never damaged a plastic tank including oversized IMS and Clark tanks. I've also crashed my IMS equipped KLR"s a half dozen times and many other people have as well - the results would seem to indicate the the thick plastic tank provides adequate radiator protection. I don't think it's stupid to add the bars (belt and suspenders), but I've decided the extra protection isn't worth the weight.....and offroad weight matters.

Smugness? ....."Dirtracks" was the 8th word in my first post on this thread. As far as tone goes, speaking for myself, I try to be as helpful as possible but sometimes my answers might be short and seem Impolite which isn't my intent....it's just that after responding to the same question dozens or even hundreds of times, I get lazy.

Cheers,
Dave
 
#31 · (Edited)
The highway bar that insan3guy made is what I was considering before I ordered my crash bars. It would have been a heck of a lot cheaper but mine arrived yesterday so I'll be mounting them.

I was disappointed that they came with no installation instructions, although it seems obvious to where they bolt. I had expected a good set of instructions that would give a sequence for mounting at the engine mount. My concern is that if I pull the two bolts, the engine will drop down because I don't know the other engine mounting points. I'm thinking I should pull the top bolt, affix the crash guard upper bolt, push through the replacement bolt, pull the lower bolt, swing the guard into position, install the lower bolt and then attach the rear bolt.

One of the problems is the forward fixing points have a section of plate welded to them which seems to serve no purpose. Additionally, I'd not be able to reattach my skid plate. It has a spacer between the plate mount and the motor mount bracket but the beefed up guard mounting point is way too thick.

I attached two pics, one of the engine mount which shows the skid plate spacer and another of the beefed up crash bar forward mount. If I remove that additional piece, I'll take it to a welder friend who has all the tools to properly cut metal and welds, plasma cutter, die grinders etc., and still save the bracket.

So, a little help from my friends. Should I remove the engine mounting plate bolts one at a time to mount the crash bars or is it best to just remove the skid plate and support the engine so it won't drop and then pull them at the same time?

I also thought that the welds looked extremely sloppy but another friend who welds such things as car frames and drive shafts assured me they were not the best cosmetically but were good and strong welds.

One good point is that the crash bars are 1 inch, which is common for highway bars and there are many highway peg options available at nominal cost. Oh and another. When I held them in place they guards came out further than Foo's with about three inches between the bracket and the IMS tank.
 

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#33 ·
So, a little help from my friends. Should I remove the engine mounting plate bolts one at a time to mount the crash bars or is it best to just remove the skid plate and support the engine so it won't drop and then pull them at the same time?
Mine were the DirtRacks for Gen-1, and I just pulled one bolt at a time.
-Pull out top bolt, and loosen bottom bolt
-Loosely attached one rack with top bolt
-Wiggle other rack onto end of bolt
-Remove bottom bolt
-Swing both racks into place
-Insert bottom bolt
-Leave both loose so I can finagle the rear mounts one at a time so subframe don't go all wonky
-Tighten up bolts in sync so pieces don't bind as they come together

Probably don't need to worry about the motor dropping, the top motor mount behind the head and good enough for the few minutes for assembly.

I forgot Navi - your scooter is a Gen-2 right?

My IMS tank is the early model without the speed holes (vents). Not sure that makes a difference.
 
#34 ·
OK, thanks for the sequence Foo. I wasn't sure it had a top motor mount but assumed it might. My old 650 Triumphs have what were called "torque stays" that bolted to the head and the frame. Yes, and mine is a Gen 2, 2008, with the vented tank. I'll follow your procedure. And do yours have that extra welded on spacer?
 
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