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Discussion Starter #1
Well, the picture speak for themselves. The passenger pegs have raddled themselves into an aluminum oval nightmare.
I plan on drilling them out and putting some kind of steel insert, but given the pegs are rivaled out.
Are these "regular" KLR650 pegs? That should be easy enough to find right?
Are the pins supposed to have grooves? (I know I could look up the part numbers, but bugging y'all is way more fun!

Thanks!
 

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Discussion Starter #2 (Edited)
ALRIGHT! No help for this one, so I got it done like this! (for those who may come across this issue in the future)

I was going to purchase a used "good" set of pegs, but all that I found were garbage as well. Mine had good rubber, so I figured I'd just drill everything out and put a bigger pin in! And wouldn't you know it, it works GREAT! I figure, If I were to drill the aluminium holes out to put a bushing in, I can always to this route first, and do the steel insert later. Plus, getting a custom steel insert made and inserted wouldn't be cheap.

FIRST purchase:
-"next largest" pin from the size removed. In this case, 5/16th was readily available here (in the US) and these holes were SO BADLY oval-ed, not even that extremely large size made them perfectly round, but it was good enough. Also, make sure you buy one that is far too long, so that you can properly pin it in the end (not have a ton of slop)
-proper drill bit size (in this case 5/16th)
-cotter pin (and small drill bit for cotter hole)

I first center drilled all of the holes, this is VERY important as the Oval will throw off your center and misalign the pegs in the end. So highly recommend you use a drill press and GO SLOW!
Second, insert the (way to long) pin and mark the proper length.
Third, Drill/ cut/ and finish the pin with the cotter pin!

VOILA! a nicely fitted pin and working pass peg!
 

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I knew you were capable, that is why I said nothing. :) Keep the peg rubbers shimmed tight & the holes can't vibrate open (as quickly).
 

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Discussion Starter #4
I knew you were capable, that is why I said nothing. <img src="http://www.klrforum.com/images/smilies/icon_smile.gif" border="0" alt="" title="Smile" class="inlineimg" /> Keep the peg rubbers shimmed tight & the holes can't vibrate open (as quickly).
Haha, right! I forgot to say I stuck a washer in there to tighten it up a bit. Any other tips?
 
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