Tusk Handguards mounting issue

[lcc]

Forum NEWB here so be nice! I just bought a set of Tusk aluminum handguards with the plastic add-ons. They look great. But I am having extreme trouble getting them mounted. The bike is a 1991 KDX250 with Renthal bars. The previous owner shaved the bars for tight woods riding, but by how much I don't know.

I can't get the aluminum guards to fit properly. When I have them mounted on the end of the bars, I can't get them to mate up to the mounts on the inside portion of the bars. If I get it close then the assembly for the master cylinder prevents the guards from getting close enough to the mounts. Even when I use a spacer on the bar ends to compensate for the shaved bars I still can not get them to mount cleanly with the inner bar mounts.

Any suggestions would be appreciated. I am open to trying another brand if they are known to mount up better. BTW, I'd like to retain standard size levers. Thanks guys!

 

[pyrofreak]

You may have to buy a pair of bars that are of standard width, unless you can trim the barkbusters down.

 

[NM_KDX200]

It's nearly always a pain, if not impossible, to fit b/busters on cut-down handlebars. I had the same issue on my KDX with 29" bars and when I finally crashed and replaced the bars, I just left them full-width.

 

[Green Hornet]

Can you re-drill a mounting hole in the bark busters to mate them properly with the clamps??

 

[gwcrim]

I put Tusk hand guards on my boy's KX85. It does have Renthals, but they're not adult width. There have been times that I had to use a vice and a big cresent wrench to twist them to fit. And as the Green Hornet was told by Kato, drilling them is an option too.

 

[strider80]

Buy some moose mini-bar handguards. They are already setup for 29.5" bars. I bought a set for my mini oversized bars and my buddy bought some for his mini standard size bars, both sets went on perfect.

 

[blackduc98]

You can move the clutch/brake lever perches closer to the steering head (within reason) to gain more clearance. You might also find that tilting them down will also give you more room if necessary, and it might be ergonomically better too.