installing rallypro handguards

[John Lyon]

Mark: This is info from a previous post. If your grips are stock, and you are going to replace them, just cut them off with a razor knife. Clean up the left bar end and the throttle grip with a Scotchbrite pad. You are going to need to drill out the end of the throttle grip. I would use progressively larger drill bits and temporarily wrap duct tape around the outside of the throttle grip to prevent it from splitting. I used a rotary tool to clean up the rough edges. Some people just cut the end of the throttle tube off with a hacksaw. Make sure the hole is large enough that the throttle does not stick when you slide the throttle assembly in to expose the right bar end. (Sounds complicated but when you do it you will know what I am talking about) Installing the left grip is easy (make sure you use the grip with the smaller hole). Put grip glue on the bars and slide the grip on. When the grip is fully on, tap the end of the grip with a rubber hammer until the bar end comes through. I use the same rubber hammer trick for the right grip but I cut out the end of the grip using a 1" piece of scrap copper pipe before I mounted the grip. Take you time and double-check everything is tight and the throttle is not sticking before you ride. John

On Tue, 11 Jul 2000 15:04:35 -0700, Weaver, Mark wrote: i'm going to put on my rally pro handguard tonight. the left side should be pretty straightforward, but are there any helpful hints for the right side? do i need to remove any of the actual throttle bits, or just cut a hole in the end of the grip? any special tools? -mark weaver _______________________________________________________ Say Bye to Slow Internet! http://www.home.com/xinbox/signup.html

[Barry Mcpherron]

Mark and the List, I too am curious about the right hand guard. I tried mounting a set yesterday and had a great deal of trouble with the brake master cylinder fitting interfering with the plastic part of the acerbis guard. I don't recall any posts about this problem so what am I doing wrong? I noticed that on my kids bikes the brake line comes out from the side of the master cylinder so no interference problem here, but the KLR line comes out the front of the cylinder. Any suggestions? My hand guards are currently sitting on the bench until i figure this one out! Thanks, Barry '91 KLR650 "Weaver, Mark" wrote:

> > i'm going to put on my rally pro handguard tonight. the left side > should be > pretty straightforward, but are there any helpful hints for the right > side? > do i need to remove any of the actual throttle bits, or just cut a > hole in > the end of the grip? any special tools? > -mark weaver > ---------------------------------------------------------------------- > [GO.com. Click to find what you're looking for] > ---------------------------------------------------------------------- > Visit the KLR650 archives at > http://www.listquest.com/lq/search.html?ln=klr650 > Support Dual Sport News... dsneditor@... > Let's keep this list SPAM free! > > Visit our site at http://www.egroups.com/group/DSN_klr650 > To unsubscribe from this group, send an email to: > DSN_klr650-unsubscribe@egroups.com

[monahanwb@yahoo.com]

I too am curious about the right hand guard. I tried mounting a set

> yesterday and had a great deal of trouble with the brake master

cylinder

> fitting interfering with the plastic part of the acerbis guard. I

don't

> recall any posts about this problem so what am I doing wrong?

I have heard of this happening; however, on my machine everything fit just so. Even the balls on the lever ends came out just short of the aluminum bars. Perhaps it is in the positioning of the controls and brake cylinder being slightly different from bike to bike? I just cut off the end piece from the throttle sleeve, and used hair spray to get the grips to slide on nice, and then it dries into glue. BBQ Bill having a bad hair day, as usual. A12 Karnivorous Lone Ranger