I have a 2006 klx 250, I ordered a set of tusk handguards and cut the end of the grip off to install and it has a 1/4 in opening that goes in about 4in. Am I the only one with these stock handle bars? Any ideas?

 

Hey YANK, first of all welcome to the forums, we almost missed you as I didn't see anything from you in the new members area. As far as the Bars go, are they grey with a stamp in the middle of them with a two digit number? If so those are the stock bars. On the throttle side of the bike, the plastic will need to be cut as well, and for some of the members on here, drilling out the weighted plug is one way to go (that's what I did) or some have actually drilled and tapped the plug allowing the bolt for your hand guards to go right in that. If you can put a picture in this thread so we can help further. Again welcome and let us know how it goes. Oh and where are you from?

 

Will be watching this thread. Ordered the Tusk handguards for my stock '09 and wondering what I'll be getting into. Might be a couple weeks before I get a chance to install though.

 

Im thinking of just taping thr existing hole its 1/4 in. just dont know if that would be strong enough.Thanks for the help.
I live in Crockett Tx. Piney woods area, lots of back roads and national forests.

 

I drilled and tapped the ends and spacered them out with washers. I used a 1/4-20 tap but don't tell anyone. Mixing metric and SAE is semi-ghetto bad form but I just used what I had at the time. The washers or whatever spacer you use on the throttle side of the handlebar must have a small enough outside diameter to fit inside the rotating plastic tube so it can still rotate. I mounted the other end of the handguard to the handlebar using the adjustable clamps that were included. My handguards fit fine and look good. I adjusted the number of washers I added so that I did not have to trim off the bump at the end of the brake/clutch levers. Now that I have the right number of washers that work, I will make a spacer to replace the washers.
I too was worried about the strength of the tapped hole until my bike slammed hard to the pavement while I thought it was safely parked on the kckstand and survivied nicely with my levers intact and the handguard still firmly in place, though scuffed badly. I like the Tusk handguards and would recommend them.

 

I drilled and tapped for 5/16. I think that should be plenty strong. Thanks for the help.