It depends if you still have the stock bars or not. My acerbis came with two sets of inserts for the ends of the handlebars, the larger for the stock bars, the smaller for aftermarket aluminum bars.

However, if you still have the stock bars and handguards, this is my suggestion as someone else had posted somewhere...(and I wishI had done this in the first place)....

In the ends of your handlebars will be "weights" that are welded in place. These weights have a hole down the center of them. The bestway forwardis to drill and tap these to the desired bolt size needed to secure the end of the handguards to your handle bar ends. Note, you will not necessarily need the long bolts that may come with your handguards and mounting kit, so i would just use a normal length allen head bolt aboutan inch or so long.This method is a lot simpler than removing the weights and filing the inside of the bars smooth to allow the mount kit inserts to fit and work, IMO. Good luck.

 

I still have the stock bars. So it sounds like the rally pros come with everything I need.

 

The stock guards are a joke. Take 'em off and save them along with all the other parts you take off. Pass the parts on when you sell the bike. I'm using Moose aluminum handguards w/plastic protectors and like them. I took 1/2" off each end of the handlebar for single track woods riding. The only complaint I have is that I also had to cut off the ball end of both levers. I don't know what brand they are, but I've seen guards where the end of the guard, that goes in the handlebar tube, drops down so you don't have to cut the ends of the levers off. After straightening out the stock bars from a couple of falls, they bend easier each time you fall, I got Moose competition XC bars.

 

I am running the Acerbis pro ralleyson renthal cr high bars(which are about the same as the stock bars) I had to run a shorty clutch lever and cut the brake lever for them to fit. I also had to take a 1" hole saw and cut clearance for the brake line that comes out of the master cylinder. Some have reported not having to do this but this is what I had to do to get them to fit look and fit right. https://www.kawasakiforums.com/m_204743/tm.htm
There is a photo of what I cut with the hole saw for the brake line in that post. I think it is the first photo.

 

Are the stock hand grips glued on? I remember doing this on my KLR and I had the cut and scape the old grips off and buy new ones! Can anyone verify that the Pro Tapers will mount up with the Pro Rallys without having to cut the the stock levers?

Cheers,

 

Buy a set of Aussie made Bark Busters
The only way to go.

 

Another vote for Zetas

 

cycra pro-bend on renthal bars

 

Cycra Stealth DX! We don't need no stinking barkbusters in the desert!

 

I cut my ***** off.