Kawasaki KLR Forum banner

1 - 14 of 14 Posts

·
Registered
Joined
·
92 Posts
Discussion Starter #1
I had just replaced a broken brake lever and got the bike looking "Ship Shape and Bristol fashion" and started riding up our driveway when our daft Dalmatian dog stopped in front of the bike.
I stopped but could not hold the bike on the hill and dropped it. the result was the new brake lever broke just below the end knob.
Rather than buy another lever I drilled through the knob then just over 3cms. into the brake lever. The brake lever I threaded with an M4 tap and opened and countersunk the hole through the brake lever knob.

The next step was to bolt the two pieces together using Nural 27 as the thread locker. The recessed bolt head and join were sanded down and sprayed satin black
The result was a better than new die-cast brake lever now reinforced with a threaded steel pin.

James.
 

·
Registered
Joined
·
5,646 Posts
Nice MacGyver move!

Otherwise . . . proper HANDGUARDS, with their metal skeletons, do a fair job of protecting not only hands but clutch and brake levers also . . .
 

·
Registered
Joined
·
92 Posts
Discussion Starter #4
So you didn't have any Duct Tape? >:)
No, I'm saving that for when my universal tank bag with magnets arrives :wink2:

Damocles Do you have a link as to where I can get these proper handguards?
My bike just has the standard (blue) plastic handguards.

James.
 

·
Registered
Joined
·
5,646 Posts
No, I'm saving that for when my universal tank bag with magnets arrives :wink2:

Damocles Do you have a link as to where I can get these proper handguards?
My bike just has the standard (blue) plastic handguards.

James.
Best buy, in my opinion, Tusk handguards with spoilers:

https://www.rockymountainatvmc.com/p/1036/9550/Tusk-D-Flex-Handguards-with-Spoilers

(Note: I had to use Chrome to access above link; Windows 8.1 wouldn't cut it.)

Fit KLRs; replacement spoilers cost about $ 12/pair in case of road rash.
 

·
Registered
Joined
·
92 Posts
Discussion Starter #6
Best buy, in my opinion, Tusk handguards with spoilers:

https://www.rockymountainatvmc.com/p/1036/9550/Tusk-D-Flex-Handguards-with-Spoilers

(Note: I had to use Chrome to access above link; Windows 8.1 wouldn't cut it.)

Fit KLRs; replacement spoilers cost about $ 12/pair in case of road rash.
Thanks for that!. I accessed the site easily with chrome and running Win 10.

Very nice handguards but as usual when I put in my Spanish address the handguards and spoilers etc. came to around $200Usd with shipping and taxes. Remember too when parcels from outside the EU arrive I have to pay another 21% plus "administration" import Taxes :frown2:
If it weren't for these money grubbing extra costs I would buy them in an instant.

Here at my Spanish home I have a fully fitted machine workshop, Lathe, milling machine, drill press, Mig/Mag welder, plasma cutter etc.
Anodised aluminium bar here is very cheap and available so I will make up some handguards loosely based on those on that web-site, and probably incorporate the stock KLR blue hand shields.

James.
 
  • Like
Reactions: rebar

·
Registered
Joined
·
1,256 Posts
I like creative ways to solve problems.

You might consider using a firm but not overly tight adjustment on the clamp at the handlebar. Just so that the lever can rotate instead of breaking when forced.
 

·
Registered
Joined
·
389 Posts
Not sure if the company CycleGear has an international presence. Their Website doesn't list anything outside of the US; but you might contact them and see. Anyhow,when I needed a set of Hand Guards, Rocky Mountain ATV was out of the Tusk versions, so I acquired the "TrackSide" versions from CycleGear for $49.99 USD. https://www.cyclegear.com/parts/trackside-aluminum-handguard-kit-with-shields
 

·
Premium Member
Joined
·
3,162 Posts
I like creative ways to solve problems.

You might consider using a firm but not overly tight adjustment on the clamp at the handlebar. Just so that the lever can rotate instead of breaking when forced.
On our race bikes we'd put a couple wraps of teflon tape under the mount and then tighten as normal; good chance it'd stay put until a crash. .....still no replacement for decent handguards though IMO.

Dave
 

·
Registered
Joined
·
92 Posts
Discussion Starter #10
I like creative ways to solve problems.

You might consider using a firm but not overly tight adjustment on the clamp at the handlebar. Just so that the lever can rotate instead of breaking when forced.
Over the years I've saved probably thousands by repairing and re-manufacturing parts for cars and electrical implements.
I started out as a Radio and TV engineer but found that mechanical issues seemed to be second nature. Most of this I put down to the excellent school I attended in the UK that as well as academic subjects such as mathematics, physics and chemistry, also included technical drawing, woodwork and metalwork.

Now after quite a few years since riding my KLR I'll get into the habit of not dropping it :smile2:
As I mentioned in another post, it's like getting together again with an old girlfriend, so I'm hoping that she remembers that I always treated her well!

James.
 

·
Registered
Joined
·
18 Posts
This is likely going to sound a bit crazy but when I buy a dirt bike, new or used, the very 1st thing I do is to slightly loosen the clamps on both the clutch and front brake levers. Not a guarantee they won't break if dropped but if they are able to move when they contact the ground, your odds increase of keep on riding BAU. Don't have to be totally loose. Just loose enough so that they can be moved.

Just a thought.
 

·
Registered
Joined
·
92 Posts
Discussion Starter #13
I did buy these and the first fitting was pretty good. I did have to put the aluminum bar in a vice and gently bend it to line up with the handlebar clamp.

The blue colour is all wrong as is the bright aluminum bar and handlebar fittings so I intend to spray the metalwork matt black and the hand guards to the same blue that matches the bike.

For £21 with free shipping I was pleasantly surprised at the quality and thickness of the protective aluminium bar. Another point I thought was impressive were the tell tale marks of milling on the aluminium handlebar clamps rather than the usual dull die-cast metal signature.

I'll take before and after photos when I get time.

James.
 

·
Registered
Joined
·
6 Posts
Not sure if the company CycleGear has an international presence. Their Website doesn't list anything outside of the US; but you might contact them and see. Anyhow,when I needed a set of Hand Guards, Rocky Mountain ATV was out of the Tusk versions, so I acquired the "TrackSide" versions from CycleGear for $49.99 USD. https://www.cyclegear.com/parts/trackside-aluminum-handguard-kit-with-shields
I installed these on my 09 klr and they hit the windshield/fairing when you turn the bars all the way. I can't figure out how to fix that, if I drop the bike my window will most likely break. Help!?!
 
1 - 14 of 14 Posts
Top