I purchased a set of Powermadd handguards not knowing how they mount to 1 1/8" bars. They require a 1/2" space in between the clutch or brake perch and the throttle assembly or electrical assembly on the left side, on my wifes bars there ain't no room. Ihave a set of xr hand guards and no dice they aren't going to fit either. Called the dealer and they said 'look online'.

So has anyone had any luck fitting a set of hand guards on the 09 klx yet? I don't wanna try a cut down milk jug either, but the idea did cross my mind. The new square milk jugs coming out won't even work....

Mike

 

i'm on an 07 but i believe the bar set-up is the same as the 09's. first, your bars probably have an insert in the ends that will have to be removed or tapped to accept the handguard bolts threads. some people have just cut the bars down, past the insert. i bought new bars to keep from dealing with any of this. i'm using cycra pro-bend handguards and love them. last but not least, inside the boxes for the high beams and the start button, there is a plastic "nub" that fits into an indent on the stock bars to keep them from spinning. the "nub" will have to be removed if you go with aftermarket bars. our bars are 7/8, not 1 1/8 i thought.

 

My Tusk D-Flex guards will be here Thursday and we're gonna work on making them fit that night. I'll be sure and start a thread with pics of how we made them fit.

 

Thanks for the responses. Yes after removing the locator nubs, rubber tape was needed on the contact areas in order to keep the housingsfrom spinning on the bars.

Let me say that the pics totally help convey the point in all the posts and I gain confidence in doing mods seen here and others. Never too many pics.

Thanks KF from a new KLX'r

 

Lowered set up for my vertically challenged wife. Forks are raised 1 1/8" above the triple clamps w/ 1mm clearance between bars & fork cap.

[IMG]local://upfiles/9886/31BB48D83B464C86B72941B66E1CA72D.jpg[/IMG]

 

another view

[IMG]local://upfiles/9886/D673FB2966544FEB9D91F5F2EC42CBD6.jpg[/IMG]

 

one more

[IMG]local://upfiles/9886/03D2E8C9857E4BB3B80B1E78A7DE29E2.jpg[/IMG]

 

I put a set of acerbis rally pros on my 09. Had to make a few cuts and grinds but they fit.



WD

 

Pro Taper Fat Bar mounts, Tag Cr hi bend bars, Cycra handguards & Solution mounts.

[IMG]local://upfiles/9886/7B4CC69A55AA423FAE1714E0C99E7E37.jpg[/IMG]

 

Had to do afew minor bends & redrilled the center mount since the forks were raised. About 1.5 hours to install. Toughest part was clearancing the throttle tube w/ grip installed for the end bar mounts so the throttle would snap shut. All in all very easy.

Mike