hand guards

[asp_125]

Ok so I finally got around to try and install my old Cycra Probend guards on the KLX. TRY being the operative word.

http://farm7.static.flickr.com/6066/6110830478_658886af31.jpg

When I cut away the ends of the handgrips, I found the ends of the stock bars plugged with a couple of welded in slugs.

http://farm7.static.flickr.com/6195/6110830110_16f8a300f8.jpg
http://farm7.static.flickr.com/6192/6110284681_65592b1c2f.jpg

The holes in the slugs are too small for the bolt that came with the Probends. The Probends also have a couple of expanding sleeves that fit in the bar, so when you tighten the bolt it holds the handguards in.

It looks like I have a few options, but not sure which one is correct:
1. Chisel off the welds and remove the slug (7/8in bar I think)
2. Drill and tap the slug for the bolt, not using the expanding sleeves.
3. Find a smaller bolt, tap existing hole.

Those who have gone this way before, which is the correct option? It also looks like I have to cut off the end of the throttle tube, right? Have I already jacked up my handgrips?

[Bueller]

I would cut off the ends of the bars far enough to eliminate the welds and get the weights (I assume) out and use the expansion sleeves. And yes if the throttle tube is solid cut or drill out the end.
Or get some different bars.

[PhL0aTeR]

personally, my first choice would be a good set of aftermarket bars.... failing that ^ what he said.

[Bashed]

I would drill and tap the existing bars just to be different from Buelller.
And yes, you need to cut off the end of the throttle tube.
Or you could spend a couple hundred and put this setup on instead.

http://www.highwaydirtbikes.com

[Bueller]

The problems I see w/Mr. B's idea is in the case of crash, sometimes the guards will move and the leverage on the bolted fastening might cause the bolts to snap off. That and you will need to save the expansion parts to use in the new bars after you bend the OEM butter bars and have to replace them. :)

[asp_125]

Thanks, looks like I'll be getting out the hacksaw. I mean, what could go wrong? ;) If it does maybe brown santa will bring me a Renthal.

That Highwaydirtbike setup looks sweet, Bash.

[Sean]

personally, my first choice would be a good set of aftermarket barsThis. ProTaper's are only $40-60 each and I feel like they are much stronger than stock.


http://www.highwaydirtbikes.com
My buddy just put some of these on his KTM990 and they are built like a brick-shithouse. No joking around with HDB

[Devaclis]

Put up a post for free/cheap dirt bars and you will find some pretty quicky. People are nice.

[asp_125]

WANTED: Free cheap dirt bars for a KLX 250. :D

Seeing as I'm temporarily in jobless land, I'm going to ghetto mod it and drill/ tap the slug.

[TFOGGuys]

WANTED: Free cheap dirt bars for a KLX 250. :D

Seeing as I'm temporarily in jobless land, I'm going to ghetto mod it and drill/ tap the slug.

MSR Steel bars are $22.49 with your CSC discount....jus' sayin'http://www.co-ar15.com/forums/images/smilies/grinser008.gif

[asp_125]

MSR Steel bars are $22.49 with your CSC discount....jus' sayin'http://www.co-ar15.com/forums/images/smilies/grinser008.gif

I like the way you think, Jim. I'll swing by in a bit. :D

[Devaclis]

WANTED: Free cheap dirt bars for a KLX 250. :D

Seeing as I'm temporarily in jobless land, I'm going to ghetto mod it and drill/ tap the slug.

I will see if I have my spare bars at home Jeff. Not sure if I gave them away yet.

[asp_125]

I will see if I have my spare bars at home Jeff. Not sure if I gave them away yet.

Just got some from Jim. Thanks TFOG!

[FZRguy]

I've have a slightly bent 7/8 steel bar you can have.

[FZRguy]

Also if you get a Renthal, the ID is smaller than stock and you may need a smaller expander bolt.

[modette99]

The correct answer is:
http://www.highwaydirtbikes.com/HDB_Shop

http://www.highwaydirtbikes.com/HDB_Shop/Images/Duke002.jpg

[Bueller]

Amazingly enough you didn't read the thread. Just answered with something that Bashed has already brought up.

[grim]

Amazingly enough you didn't read the thread. Just answered with something that Bashed has already brought up.

It never fails every time moddette jumps In a day late and a Dollar short doesn't read anything and posts. You sir are a winner! :up:

[asp_125]

I got an MSR bar from TFOG. /endthread

[modette99]

Amazingly enough you didn't read the thread. Just answered with something that Bashed has already brought up.

Amazingly I did, nor did I care that he posted a link too...just backing it up its the way to go. Besides I post a picture :boobies:

[asp_125]

.. :boobies:

Where? I don't see no :boobies: ?

[Bueller]

Amazingly I did, nor did I care that he posted a link too...just backing it up its the way to go. Besides I post a picture :boobies:
Unfortunately your response had nothing to do with the question that Jeff was asking.

[modette99]

Yes, it did...he was asking about some POS handguard he has and some welded in thingy and whether to tap it, knock it out or tap is to a smaller hole.

Replace POS bars, and buy new ones, then buy a good set of bark busters....to which I posted saying go with highwaydirtbike ones...plus made in CO.

It had everything to do with his question...my response in short words stop using POS parts.

[brennahm]

Facepalm.

Bueller...let it go...it's like trying to explain racing to a stunter.

[Bueller]

Facepalm.

Bueller...let it go...it's like trying to explain racing to a stunter.
No shit talk about a private Idaho