For those that installed aftermarket hanldebars on their bikes
----Did you guys drill both sides of the new handlebars to install the LEFT (light controller) and right(starter) boxes?

 

I changed my handlebar on an other motorcycle (not klx) featuring the same "good-idea-for-alignment-but-create-a-weak-spot" holes.

Instead of drilling the new handle bar, I preferred to file the alignment pin of the controllers. I could also adjust the angle of each controller for my needs. Of course, if the screws weren't tight enough, the controller unit had the tendency to move. Instead of over-tightening the screws and break the plastic, I used a bit of duct tape where the controllers would go. I cut off the excess and I end up with a clean job and controllers box right for me.

Good luck!

 

Don't drill alloy bars. The OE items are steel, so no problem. Just cut of the plastic tabs and refit.

 

I did a drill job and ended up not happy with it anyway. I would also recommend cutting the tab and then using a shim of some sort to keep it tight at the place you want, that's easier to fix and adjust than a hole

 

Why were you unhappy?

 

Why not drill alloy bars?
Are all the aftermarket bars alloy? (I purchased the Pro-Taper SE)

 

As everyone has said , remove the nubs from the control. Without the nub you can position it at any angle that suits you. If it seems too loose wrap tape around the bar where the control mounts. Drilling holes in any bar will weaken it. Yes, your bars are made out of an aluminum alloy.
Dan

 

I was unhappy because even though I "thought" I had everything mocked up 'just right' once it was all buttoned up tight and I went for a ride I ended up tipping the bars a bit more forward than I had originally thought, and then of course it lined up differently than I was originally hoping. No real harm done, but frankly it would have been easier and faster to just get rid of the nub and have total adjust-ability even if I move my bars all over the place over time. It doesn't harm anything valuable to remove the nub.. holes in metal are more permanent.

 

 

WOW! Which handlebar is that?