Kawasaki KLR650 Tusk Crash Bars Installation

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Tusk Crash Bars are perfect for your dual sport and adventure motorcycle riding needs. Tusk Engine Crash Guards are made from tough 1" powder-coated steel tubing so they will hold up on all your adventure motorcycle rides. The 3-point mounting system ensures strength while providing crash protection to your engine, vital components, and shrouds. In this video we point out all of the steps you'll need to take to successfully install your personal set of Tusk Crash Bars on to your KLR 650! Fits with: - Original Kawasaki Skid Plate - Ricochet Offroad Skid Plate - SW -MOTECH Aluminum Skid Plate. Get all of your adventure bike needs available at www.rockymountainatvmc.com. Get Ready!
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[@danshockley115]

Thank you for this helpful video, which I used to install the bars and Motech Ricochet skid plate on an ‘09 KLR 650 last night. When I removed the factory skid plate, I was surprised and initially discouraged to find that there are some metal tabs to which the front of the OEM plate attaches bolted and apparently welded to the triangular engine mount. Just wanted to comment that the crash bars CAN be installed with those tabs in place. It is a little more difficult to access the lower bolts if you leave those on, but you’re left with extra protection in the gap between the bars and Ricochet plate and some folks attach a tool tube there.

[@TitanFlare]

Idk about you, but it was MUCH more difficult. There was no room to do anything with those tabs, my hands were bleeding all over by the time I finished. Maybe like 3 universal joints and extensions would have done it

[@DustySquitoNM]

I actually just bought these and got them installed. This video was super helpful in getting everything done up. Thanks, yall!

[@Sunofasack]

Love the video!! Doing my install this weekend on my new to me, ‘18 KLR650

[@ryanheatherly3631]

Thank you for this! Great help!

[@MrPepper312]

No problem installing the crash bars but cannot get the tank on correctly to align with the side panels. The two mounting bolts on the tank match up with frame but the rest of of tank is too high. Don't want force it. Anyone else had this problem.

[@69adrummer]

So, do I lose my Eagle Mike Subframe bolts?!?! Are those bolts just as strong?!

[@debraziebert3005]

Do you guys remember what year KLR this is? I have a 2012 and the gas tank vent hoses / lines are definitely different than in this video

[@rmatvmc]

This is a 2008 model.

[@Hansengineering]

CA models have those vent hoses.

[@STEVEM730]

Installed these on a 2018 KLR and one side is sticking out farther than the other. Not a dealbreaker but kind of annoying to look at.

[@malcolmnuttall3165]

It has too to allow for the radiator.

[@TitanFlare]

@@malcolmnuttall3165 the side with the radiator is the closer side. It’s the coolant reservoir side that sticks out further

[@YoyoBandalore]

I finally got my Tusk Crash Bars installed on my 2015 KLR 650 with HTP (Happy Trail) skid plate. They look great and I haven't had to use them yet. ;) I do have one issue though. I am encountering the same vibration issue that others have seen/felt. At low RPMs (~2500 RPM), there is a resonant vibration that I can feel in the handlebar and foot pegs. Do you have any recommendations on how to eliminate or at reduce this vibration? I'm not sure if some sort of rubber mount might help or not. If you have any recommendations on how I might remedy this issue, I would appreciate hearing them. Thanks.

[@liberalh8tr405]

Same exact situation on my 2012 klr.

[@AzMtnThumper]

Has anyone mounted any bags to these crash bars? I'd like to put my tubes, tire spoons and tool roll on the crash bars if possible. Wolf man Rollie bag? Altrider synch? Anything else??

[@nose2wind872]

Can you get the carburetor off with that bar in place?

[@rmatvmc]

*Nose2wind-* Looks like at min 2:30 it would be a very tight squeeze to get the carburetor out. We have yet attempted to try and pull the carb out. If anything, you could pull the one bolt out to loosen the crash bar to give you enough wiggle room. Hope this helps you out. Thanks

[@Coywolfie]

i purchased these tusk bars, but my right tank shroud is broken near the bottom bolt.should i wait to order a new shroud before putting the tusk bars on? Or can I get at the broken shroud after install thank you in advance.

[@rmatvmc]

It'll probably be a little tight fitting molding it in to position, but i'm sure you could make it work.

[@HorsieCloppenHoof]

Idk if you still respond. But do I need to siphon the gas out of my tank first?

[@rmatvmc]

No its fine if some fuel is in your gas tank, it'll just be a little heavier when you take it off. As long as you turn your petcock to the off position like we show here at 1:17 you'll be good to go.

[@HorsieCloppenHoof]

@@rmatvmcAwesome thank you so much. I have a almost full tank still on my bike since I haven't been riding much lol x)

[@rmatvmc]

You're welcome! Maybe you can use this as an excuse to ride some more before you take your gas tank off!

[@pinkiewerewolf]

Anyone know where to find replacement mounting hardware? I'm trying to piece this stuff together but I'm not having luck. The metric spacers are proving to be impossible through the internet and locally. I just installed the Eagle mike's through bolt to the subframe and got ready to install the bars but can't find my hardware kit. Thanks in advance.

[@rmatvmc]

You just need the mounting hardware for the Tusk Crash Bars? If so, just give us a call and we should be able to track some down for you.

[@pinkiewerewolf]

@@rmatvmc i called yesterday but you guys were out of them. Sent me the instructions, which I appreciate but I can't seem to locate these metric sizes or the correct spacers. I emailed today and they are looking for me.

[@aajawo]

Hey will these work with the stock skid plate? And what about the SW-Motech skid plate?

[@rmatvmc]

+aajawo Straight from our Product Details page off our website.. Fits with: - Original Kawasaki Skid Plate - Ricochet Offroad Skid Plate - SW -MOTECH Aluminum Skid Plate

[@timallen3166]

Why can't I find TUSK crash bars to buy for my 2013 Kawasaki klr650?

[@rmatvmc]

+Tim Allen You can find them here: www.rockymountainatvmc.com/p/1062/-/1092710/Tusk-Crash-Bars-Engine-Guards-Black part# 1560870001 - Currently out of stock sorry.

[@rmatvmc]

+Tim Allen You can find them here: www.rockymountainatvmc.com/p/1062/-/1092710/Tusk-Crash-Bars-Engine-Guards-Black part# 1560870001 - Currently out of stock sorry.

[@Sertao2013]

I take it since you didn't add a year of the bike this crash bars will work on all years right ?

[@rmatvmc]

We have these available for the generation 2 KLR650 (2008-2018). You can check out more info on the Tusk Crash Bars - Engine Guards here: www.rockymountainatvmc.com/parts/tusk-crash-bars-engine-guards-p

[@Sertao2013]

@@rmatvmc So if its not for all the klr 650's why don't you put the years it fits ? I can't find a crash bar like the one your showing in the video on the web site to fit gen 1 . Do you make one or not ?

[@TitanFlare]

It is NOT this easy with the stock skid plates. The brackets make putting the spacers in nearly impossible, I had to use a combination of tape, hammering, pole magnet, and every other tool in the book you can think of. It was not fun. Looking back I have no idea how I actually even got them installed

[@jizohn85]

i also would like to know if it fits with the happy trail skid plate?

[@rockymoto1787]

Would this fit on a 1st generation klr650.

[@rmatvmc]

Unfortunately, the Tusk Crash Bars are made for the 2008+ KLR650's but we do have SW-MOTECH crash bars available for the first gen's. You can check those out here: www.rockymountainatvmc.com/parts/sw-motech-crash-bars-engine-guards-p

[@AlanTrades]

How does this compare to the swmotech bars?

[@techydog7854]

About $100 less. I can't seem to find anyone saying one better than the other.

[@b1pig]

Great..... Now I have a crisis on which guards to buy.....

[@rmatvmc]

+b1pig We were hoping to simplify that problem.. (hint hint) :)

[@b1pig]

+Rocky Mountain ATV MC I looked at the item description... but I still have to ask. Do you think it will fit with the JNS skid plate as I already have one on my KLR? It "looks" like it should fit.... buuut..... if all it requires is some trimming around the upper part of the skid plate, i'm good with that. Since there is a spacer, that eludes to the fact that I can mount it over the JNS hardware.

[@rmatvmc]

+b1pig I asked around and we did have a shop bike come in with the JNS skid plate and it mounted up. We may have had to trim a little bit off the skid plate, but it fit and looked great. Let me know if you have any other questions about it.

[@b1pig]

+Rocky Mountain ATV MC that was it.... with that, you definitely simplified my problem. (hint taken). thank you. its actually going to be really easy to convince the wife. the bike in the video has the same color/graphics as mine. :)

[@rmatvmc]

+b1pig The Tusk Crash Bars don't only armor up and protect your dualsport bike, but they give it that real aggressive adventure bike look and feel. They're a must have on these full figured machines :)

[@steelcityadv3190]

will these fit with the htp skid plate?

[@jizohn85]

+SteelCityADV did you try it?

[@steelcityadv3190]

+jizohn85 no I haven't

[@rmatvmc]

+SteelCityADV Straight from our Product Details page off our website.. Fits with: - Original Kawasaki Skid Plate - Ricochet Offroad Skid Plate - SW -MOTECH Aluminum Skid Plate

[@rmatvmc]

+jizohn85 Straight from our Product Details page off our website.. Fits with: - Original Kawasaki Skid Plate - Ricochet Offroad Skid Plate - SW -MOTECH Aluminum Skid Plate

[@steelcityadv3190]

+Rocky Mountain ATV MC Thanks for the response. I don't have any of those mentioned skid plates. That is why I asked the question to see if someone has the one that I have.

[@AlanTrades]

What's your rear crash bars called?

[@rmatvmc]

Tusk Crash Bars.

[@AlanTrades]

Rocky Mountain ATV MC did you mount anything to them?

[@chriscrowder8505]

Oh boy do you want a cookie?

[@BugTheRoot]

Be aware that these will NOT fit the 2022 model.

[@rmatvmc]

That is correct. We not not list these are fitting the newest generation KLR650.

[@bobbythoms2078]

yes I'm first XD