Kawasaki KLX 300 New Handlebar! 5 Tips for Installation
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- Опубліковано 3 жов 2024
- A brief video with tips for installing new handlebars and grips on a Kawasaki KLX 300 with bonus footage at the end for installing a power source for charging devices. Important note, I decided not to drill plug holes in my handlebars to fit the left and right side housing. Choose the option that works best for you as I've seen at least one other installation video that the installer drilled holes in his new handlebars to best secure the housing.
KLX 300 Mods:
Emperor Heavy Duty Skid Plate - www.emperorrac...
T-Rex Luggage Rack -www.t-rex-raci...
Double Take Enduro Mirrors
Mods related to this video:
*ProTaper EVO Windham MX/RM Mid Bend Black with Tusk Universal Big Bar Clamp (purchased as a kit) - www.rockymount...
*ProTaper Pillow Top MX Grips Black/Grey Black
*Tusk D-Flex Pro Hand-guards (Orange spray painted black)
*These three items were purchased at Rocky Mountain ATV.
Power source:
YONHAN Motorcycle USB Charger SAE to USB Adapter, Total 36W Dual USB Type C PD & Quick Charge 3.0 with Voltmeter & ON/Off Switch
www.amazon.com...
I also used a leftover cable battery hookup with built in fuse to connect from the battery to the YONHAM charger cable under the seat.
Music:
Meet & Fun! by Ofshane
On my 2023 KLX300, I went with Pro Taper CR High bend bars, and ended up getting new throttle tube and cables, new clutch cable, new levers (kept the original perches), and new electric controls on both sides. I got the2023 KLX300R throttle tube and cables to work, as well a a 2023 KLX300R clutch cable. The overall length of the outer sheath is a bit longer on the 300R cables, although the center cable for the clutch could be 1/4 inch longer. The center cables for the throttle cable could be 1/2 inch shorter. I used Motion Pro Run/Stop and Start switch combo on the right side, and on the left a Tusk Compact Control Switch w/ Headlight Option. Now I can adjust my levers properly, and don't have all that 1970s ugly crap on my machine. I did all the other mods you could do, and found that all here on UA-cam. The only things I had to figure out myself were the cables, throttle, and the electric.
Nice! Thanks for the comment, this will help those looking to make the handlebar change.
I recently went through this with upgraded Protaper CR High bend, Acerbis handguards, and a universal windscreen. Real estate on the handlebars gets pretty crowded, but it all fits. If you want to put handguards on the KLX, do it at the same time as the new handlebar installation, otherwise, you have to drill out the ends of the stock handlebar. My lessons learned, 1) I don't know how expensive a new throttle tube is, but any price is worth not having to scrape off the old grips and you can then go back to stock if you want to sell your bike and keep the new handlebars, 2) I wished I would have drilled the location holes into the new handlebars, instead of dremelling off the location tabs in the controls, again, this would be more stock and the controls slide a bit without the location tabs, 3) film disassembly of the throttle control, its a PITA to get back together, most of the time was spent just realizing the location tab won't allow it to fully seat on the bars, unless you drill a location hole, or dremel off the location tab...
Thanks for sharing this comment, it helps provide more perspective on the process of installing the bars. I considered the new throttle tube but needed to have the bike ready the next day for a ride. I also thought about drilling location holes in the handlebars but was concerned about damaging the integrity of the bars. With properly placed duct tape, my stay in place. The location tab drove me crazy for the same reason, I thought I was not putting together the throttle control as well. Hope you are enjoying the bike and the new bars. Cheers
With that high Bend bar, did your clutch and brake cables still fit right or did you need longer ones
I also have a 2021 KLX300 Dual Sport. Liked commented and subscribed 😊
Enjoy that bike! I’m loving mine. Thanks for the comment and subscribing! Cheers
Just had a yahoo pull out in front of me on my 2020. It totally bent my bars. My mechanic told me that’s why my forks are probably okay. Do you think when laying down your bike on the road, with stronger handlebars, that it’s possible more damage would be done to the bike?
Hmm, not sure about that but I've had off-road drops with the new bars where the forks twist a little but are easily adjusted back in place. It's hard to damage the forks vs. twisting them within the triple clamps.
You didn’t have any issues with your clutch cable being to short at full turn to the left? With the bend you chose? I got the cr high bends and upon test fitting my clutch cable is o tight with all the slack possible. I’m considering getting a smaller bend
I did not, it was a little tighter after installing new bars but the Tusk handlebar riser did not lift the bars much vs. other risers out there that might lift it to much for the cable to handle. Also pay attention to how far forward you have the pro-taper bars. The further they are mounted forward vs. backwards toward the rider, the tighter the cable.
@@theEHWAZ I noticed you also didn’t drill the hole in your bars for your controls. How well has that worked for you have you had any movement afterwards. I’m debating whether or not I want to grind the plug off and use the friction tape method to keep them from moving or if I want to drill the bars, which I know can cause “potential” fatigue/failure issues.
You have any issues with the cables being too short with that bend of bar?
Yes, it just barely worked with stock cables but I had to adjust the throttle cable at the lever and further down the cable. If you follow the throttle cable down you will see an adjustment bolts that a give you a little more free play as well as adjusting at the clutch lever. Use your manual to adjust appropriately. Also moving the handle bar back and forward slightly makes a difference.
I have a 2009 KLX Supermoto SF the guy I bought it from change the handlebars I need 2 in on my cable for my clutch can you put a quick shift clutch lever in there I don't know why I did this everything's too tight what cable did you use
I kept the stock cable and didn't have any cable length to spare. It fit just perfect but if I bought a higher riser or handle bars with a bigger bend, the stock cables would not have worked. I had to make a few adjustments to the cable connectors to give me a few extra centimeters though.
You would think in 2022 manufactures would put USB charging ports on all bikes. Royal Enfield does it for bikes that cost much less
Totally agree, it's a simple and inexpensive addition that manufacturers should include.
Are you in the Atlanta area? We should get together and ride in the N Ga Mountains
Most of my rides take place n N. GA. I'm still discovering the off-road trails out there and have explored them through events and the weekly Sat. morning ride. If you ever join the Sat. group rides maybe we can ride then. We can DM details.
Thanks for posting.
***. How much rise did you get ?
The clamps have a 3/4" rise but you can compensate for it by purchasing Pro-Taper bars with different bends.
I am curious: one reason I'd install new handlebars is that I do not like the low position of the stock bars. You stated that you had yo use the Tusk riser/adapters that are 3/4" taller, but that the bars compensated for this rise in height. I'd actually want the extra height, so is the compensation in the particular bend you chose? i.e. the rise is lower than stock? Also, I like the Tusk brush guards as well, but did you say they will not fit without modifications? THanks in advance!
The ProTaper EVO bars I installed with the Tusk big bar clamps are definitely higher than the stock bars. I can feel a noticeable difference, especially when standing. I also placed the stock bars behind the ProTaper bars at the level of the stock base clamps and confirmed the new bars are higher vs. the stock so I believe the compensation for the 3/4 inch clamp rise is not full compensation, just partial. The challenge I ran into was finding a new handlebar with a higher rise that worked with the stock clutch cable and brake line. WIth too much rise you will also need a significant adjustment in the cable and brake line or replace them with longer ones. I recommend you look at the sizing chart located in the handlebar link I provided at Rocky Mountain ATV. They list the bar height, bend, and width for the different bar and clamp kits. The bars and clamps I installed allowed me to keep the stock clutch cable and brake line although I had to adjust the clutch cable slightly.
Regarding the Tusk handguards, mine came with extra bar insert tension screws and spacers since I had the Adventure motorcycle version that I originally had on my KTM 790 ADV R. I used a wider spacer on the clutch side of the bars and a shorter spacer on the brake side to make it all work but it was not that difficult. It took a little trial and error but fits pretty well and provides plenty of protection. If you look closely at the end of the video you’ll notice the spacers between the handguard bars and handlebar ends. I probably could have made it work without the larger spacer as well but using it made the install process go quicker in my case.
Hope this helps and thanks for watching.
@@theEHWAZ Thanks a bunch for the input! I always struggle with handlebar changes.
Are the pro taper bars ends threaded so you are able to just screw in the hand guards. Or did you have to do any modifications?
The ProTaper bar ends are not threaded. The lockbolts that are supplied with the handguards expand within the bar ends when you tighten them thus locking them in place. I had to use a spacer on the left side of the bar to line things up properly but other than that it was straightforward to install, It just takes a little bit of repositioning to find the right placement. Rocky Mountain ATV has videos showing how to install them that is helpful. Thanks for watching!
I don't think any bars come threaded. I tap mine.
your video is so helpdul bro you dont understand😭
Glad it helped!
PLease never put music behind your videos again. Comepletely pointless & quite annoying
To each their own, I and others enjoy the music. I enjoy and accept feedback but only when it's constructive and delivered with positive intent.