Page 1 of 1
handguard install causing throttle restriction
Posted: Mon Jan 11, 2010 10:14 am
by todd_mckinnon2000
Am I the only one to have this problem? Bought Acerbis handguards for my 05 KLR650 from Dual-Star and when I installed the right side tightening it down caused the throttle not to move freely and loosening it up made the right handguard too lose.
Have been studying a bit and seems that two other manufacturer may be using a split wedge locking system whereas the Acerbis as I recall was a system that just spread the bolt out from the middle outward to press against the inner walls of the handlebars.
I had to take them off and having regrets because I paid a lot for them. Can anyone offer any ideas or another product that works better. I have two KLR's 05 and 03. I suppose I am hoping to find a better bolt or lock down system for the Acerbis set and then I will probably buy a second set for the other bike and am free to choose another vendor.
I found a couple of mentions on youtube, but nothing that solves my specific problem. Seems funny that no one else is mentioning this so I wonder if I am doing something wrong. I noticed some vendors refer to two different size options for the handlebar and I don't know what diameter my klr's are. I trusted that DS gave me the right set. Thanks for any help as I try to put better handguards on the bikes.
handguard install causing throttle restriction
Posted: Mon Jan 11, 2010 10:34 am
by k650
I seriously doubt the clamp inside the handlebar is causing it to bind
by distorting the handlebar as it appears you describe. What is most
likely happening is when you tighten the clamp it is binding on the end
of the throttle tube. After you have the handguard tightened into your
desired position simply loosen the fasteners holding the throttle housing
to the handlebar and move it inward enough so when you retighten the
throttle housing it no longer binds.
Walt
> -----Original Message-----
> From:
DSN_KLR650@yahoogroups.com [mailto:
DSN_KLR650@yahoogroups.com] On
> Behalf Of todd_mckinnon2000
> Sent: Monday, January 11, 2010 11:10 AM
> To:
DSN_KLR650@yahoogroups.com
> Subject: [DSN_KLR650] Handguard Install Causing Throttle Restriction
>
> Am I the only one to have this problem? Bought Acerbis handguards for
> my 05 KLR650 from Dual-Star and when I installed the right side
> tightening it down caused the throttle not to move freely and loosening
> it up made the right handguard too lose.
>
> Have been studying a bit and seems that two other manufacturer may be
> using a split wedge locking system whereas the Acerbis as I recall was
> a system that just spread the bolt out from the middle outward to press
> against the inner walls of the handlebars.
>
>
> I had to take them off and having regrets because I paid a lot for
> them. Can anyone offer any ideas or another product that works better.
> I have two KLR's 05 and 03. I suppose I am hoping to find a better
> bolt or lock down system for the Acerbis set and then I will probably
> buy a second set for the other bike and am free to choose another
> vendor.
>
> I found a couple of mentions on youtube, but nothing that solves my
> specific problem. Seems funny that no one else is mentioning this so I
> wonder if I am doing something wrong. I noticed some vendors refer to
> two different size options for the handlebar and I don't know what
> diameter my klr's are. I trusted that DS gave me the right set.
> Thanks for any help as I try to put better handguards on the bikes.
>
handguard install causing throttle restriction
Posted: Mon Jan 11, 2010 10:36 am
by Fred Hink
Todd, Make sure that there are no burrs inside the throttle sleeve where you cut the end off and that there is sufficient clearance between the throttle sleeve and the hand guards once they are tight. Make sure nothing is rubbing the hand guards once they are tight. Which model Acerbis hand guards did you get? More than likely you have the Acerbis Rally Pro and these should fit your KLR just fine. I suppose anything is possible and over-tightening the clamps may have deformed the handlebars but I doubt it. I check your throttle sleeve as this has to be smooth inside and also needs clearance on the end so it doesn't rubb. All handguards are made to fit either your stock steel handlbars or aftermarket aluminum handlebars and are all 7/8" OD. If you have the "bulge type" handlebars, there is usually an adapter that can let you use your hand guards on these fat handlebars. The mounting hardware is the same for the stock and aluminum handlebars on the outside but the inside hardware is different. I like the way the Maier Woods Pro mounts and fits the KLR better than Acerbis. The aluminum bar is also slightly larger and stronger too. Maier offers several different types of plastic hand protection to fit these bars, so you can have small guards or large full coverage guards to fit your needs. Good luck and let me know what you find out.
Fred
www.arrowheadmotorsports.com ----- Original Message ----- [b]From:[/b] todd_mckinnon2000@... [b]To:[/b]
DSN_KLR650@yahoogroups.com [b]Sent:[/b] Monday, January 11, 2010 9:10 AM [b]Subject:[/b] [DSN_KLR650] Handguard Install Causing Throttle Restriction
Am I the only one to have this problem? Bought Acerbis handguards for my 05 KLR650 from Dual-Star and when I installed the right side tightening it down caused the throttle not to move freely and loosening it up made the right handguard too lose.
Have been studying a bit and seems that two other manufacturer may be using a split wedge locking system whereas the Acerbis as I recall was a system that just spread the bolt out from the middle outward to press against the inner walls of the handlebars.
I had to take them off and having regrets because I paid a lot for them. Can anyone offer any ideas or another product that works better. I have two KLR's 05 and 03. I suppose I am hoping to find a better bolt or lock down system for the Acerbis set and then I will probably buy a second set for the other bike and am free to choose another vendor.
I found a couple of mentions on youtube, but nothing that solves my specific problem. Seems funny that no one else is mentioning this so I wonder if I am doing something wrong. I noticed some vendors refer to two different size options for the handlebar and I don't know what diameter my klr's are. I trusted that DS gave me the right set. Thanks for any help as I try to put better handguards on the bikes.
muffler mods with rivets and rtv.
Posted: Mon Jan 11, 2010 11:17 am
by Thomas Komjathy
Talking like Igor "please..pictures Master, pleeeaaasssseee...." Sounds great, I will do this. I have a spare muffler I will do it on. Thanks Eddie
TK
[b]From:[/b] transalp 1
[b]To:[/b] KLR650 list DSN_KLR650@yahoogroups.com>
[b]Sent:[/b] Mon, January 11, 2010 11:51:44 AM
[b]Subject:[/b] [DSN_KLR650] Muffler mods with rivets and RTV.
I've had good luck with rivets and RTV on other bikes. That said, the HMF exhaust tip for the KLR arrived Friday afternoon. Saturday morning, I bought a 2 in. bi-metal hole saw and 1 inch dowel from Home Depot and went to work........ .after I discovered a 1 inch dowel wouldn't fit in the exhaust and replaced it with a 6 in. section of a broom handle. LOL I went slowly with the drilling as recommended - using WD-40 as a coolant for the saw. It chewed right through the muffler in only a couple of minutes. Instead of using rivets right away, I opted to fit modified clip-type blind nuts and screws first. Dummy me forgot to get a sink screen to use as a "spark arrestor" and wanted to be able to add one easily in the near future. I'll just rotate the HMF tip slightly, drill smaller holes next to the 1st three, seal, rivet and be done. I checked and the larger rivets I have countersink the heads perfectly in the recessed holes of the HMF tip. =) eddie
----- Original Message ----- [b]From:[/b] klrsisfiddy@... [b]To: [/b]transalp1@...;
DSN_KLR650@yahoogroups.com [b]Sent:[/b] 1/9/2010 3:10:57 PM [b]Subject:[/b] Re: [DSN_KLR650] Re: i need help pls - Muffler Mod Instructions with Photos
Eddie
When you get that thing glued on there and some rivets, please let me know how it works. I want to get one, but I'll let you be the Guinea Pig on this one. I'm thinking the damping of the hi temp silly cone and some rivets would do the trick.
Cheers
TK