KTM fork guard install for DRZ400/S

Has anyone installed the KTM fork guards for the S model without cutting the light mounting bracket?

I hard there some people on TT that have done it this way, if anyone has any information on this mod please let me know?

Thanks, :thumbsup:

Thanks smcalpac

This was were I got the parts list from but that thread is for the "E" model application, the "S" model is a different application. Perhaps you know he way around the mounting bracket on the "S" without cutting it, then welding it back?

I am not aware of anyway around doing the mods to the bracket. I have an E model with SM guards on it and currently on a 04 S frame with a plated 06 SM frame about to go into use, so mine is a conglomeration of parts. The cutting and welding isn't too bad to deal with.

There is a simple way. Throw away the stock headlight and install a Cyclops. It will look bitchin with your new fork gaurds!

After looking at mine, it looks as if you could ...maybe....install the guards under the lower fork clamp. With that said it would sit pretty low and may get hit if the forks compress on a hard hit.

Installed this way, they most likely would not fit as solid.

One person posted that he used a wire twisting tool to install his. I believe he must have cut the clamps off the KTM guards so that they would not hit the headlight mounts and then used the wire twisting tool to securely mount the guards to the fork.

There may well be a couple more good ideas floating around. If so I'd enjoy hearing them.

I'm the guy who cut off the KTM guard bolt/screw bosses and instead used a Clamptite tool to wire clamp them to the forks:

http://www.clamptitetools.com/

Its worked great, probably stronger than the original plastic clamps. I don't weld or have a welder so I gave this a shot. You could probably use a hose clamp or something else if you didn't mind the look.

KTMwireClamps.jpg

I'm the guy who cut off the KTM guard bolt/screw bosses and instead used a Clamptite tool to wire clamp them to the forks:

http://www.clamptitetools.com/

Its worked great, probably stronger than the original plastic clamps. I don't weld or have a welder so I gave this a shot. You could probably use a hose clamp or something else if you didn't mind the look.

Now that's the info and picture I was looking for, thanks gpdsign :thumbsup:

I'm going to give that a try....:worthy:

Bump.

Would like to see these mounted on a "S" with modified fork brackets.

Anyone???

Tipsy

Bump.

Would like to see these mounted on a "S" with modified fork brackets.

Anyone???

Tipsy

The FAQ write up with pics and part numbers will be ready in a day or so
The FAQ write up with pics and part numbers will be ready in a day or so

Looking forward to it!

Tipsy

Gpdesign, Can You Post More Pics Of The Guards On Your Bike????

The FAQ write up with pics and part numbers will be ready in a day or so

Hey Bronco, I know your kinda busy(seriously), but any headway being made on the FAQ write up? I'm kinda interested in this mod.

Thanks,

Shawn

Bump.

Gpdesign, Can You Post More Pics Of The Guards On Your Bike????

I missed your post earlier, Heres the only other photo I have at the moment.

KLXgp.jpg

I missed your post earlier, Heres the only other photo I have at the moment.

KLXgp.jpg

The fork guards look great. How do you like them so far?

The fork guards look great. How do you like them so far?

I like them. I think they look better than the stock rubber things, so far the fork tubes are undamaged so they must be doing their job. I do put on some seal savers when I go dirt bikin' which is most of the time.

Can you tell me either the part #s for the guards or the model KTM they are off. I really want to do that mod with the Carbon wraps on the lower sections. The forks would look great that way.

Check out post #2:

50301090250 Clamp protector guide '98

5460139000030 Fork protection guide R/S '97

5460129000030 Fork protection guide L/S '97

another 50301090250 Clamp protector guide '98

Middle

50301093000 Fork protector R/S black '97

Bottom

50301092000 Fork protector L/S black '97

all are from KTM 250EXC bikes.

Damn, what a pain to order I bet. What does all this run from a dealer?

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