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Installing Rally Pro Handguards

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OK, another stupid noobie question...

I bought a set of Acerbis Rally Pro handguards. However, when I put the medial (inboard) bracket on the bars (stock) I can't get the plug end at the end of the bar all the way in. Do I need to trim or cut some of the inboard end off or is there some trick to mounting these?

Thanks...

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Have you changed your bars to aluminum ones? If so they take a different end piece. If not have you turned the screw ccw as far as it will go?

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Not quite sure what your problem is from the description but....

When I put the rally pro's on mine I needed a 5/8 inch spacer between the handle bar end and the guard. The inboard end of the guard was hitting the fork tube. I used a SS nut from the hardware store. I also remember someone here used a plumbers tube.

When I installed the Jim Button bars they were wide enough I no longer needed the spacer. Nor the nylon tubing that slipped over the bar expander. Hope it helps :banghead:

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I've only done these on KLRs before but I find that you have to leave the inside clamps VERY loose while you fit the end caps and then work everything up a bit at a time until they're all tight.

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Ya, that's basically the problem. the bars aren't wide enough AND the inboard end is up against the clamp. SO, your idea for a spacer is a VERY good one. That's what I will be doing, I think. OR I could shave away part of the inboard end...not sure, will try the spacer idea first, then if that doesn't fly start cutting. thanks for the advice.

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OK I realize I am a little slower than most, but when I removed the bar end weights I failed to remove the rubber mounting things in the end of the bars.

As soon as I removed these my Acerbis Rally Brush guards fit fine.

-

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OK, I feel like freakin' McGuyver here...In order to fill the gap between the end of my bars and where the outboard end of my handguards were situated,

I went out to the local hardware store and dug around in their bolt/crew tubs for a while until I found something I thought would work. I found a nylon spacer/bushing doohicky. Unfortunaetly it was slightly too narrow internally to fit over the bar-end insert. So, I bored it out a bit and it fits great. It fills the gap nicely and the handguards fit really well now :banghead:.

I'm new to working on my bike so alas, even these little things are pretty exciting!!! :banghead:

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