Handlebar vibration; got caulk?
I really like the bend of the stock bars, but was seriously considering putting on aluminum bars to cut down on the vibration a little. I have aluminum bars on my KLR650, and it is much smoother than my buddy's KLR with stock steel bars.
I started scouring the forum trying to determine a good set of aluminum bars that were recommended by others. I came across a post from a guy who put caulking compound in his mirrors to cut down on vibration. I wondered if it would work for the handlebars themselves.
I had previously tried lead shot in the bars of my buddy's KLR, which didn't seem to help. I thought "Why not? I've got nothing to lose but a little time and some caulk".
I removed my KTM handguards, and opened up the switch pods (didn't want to fill them with caulk through the locating hole). I had previously removed the OEM cable guides that fit into holes in the bars (they were in the way of the handguards). I loosened the clutch and brake perches and moved them out of my way.
This left me with 6 holes in the bars. I had a tube of Bathtub caulk, from a previous project, which was mostly full and so this mod was going to be "free".
I shot caulk into the end of the bar until it started coming out the switch pod locating hole on that side. Then I screwed a bolt into the end of the bar. I then shot caulk into the switch pod locating hole until it started coming out the cable guide hole. I then taped over the previous hole, and moved to the next. Repeat as necessary until you run out of holes.
This can be messy, so go slow. I kept a box of tissues and a waste basket handy to clean up as I went along. When I was done, I removed the tape from the holes and remounted all the parts I took off. (Remounting the right switch pod and getting the throttle cables located correctly is a patience-testing endeavor).
This mod costs almost nothing (generic store brand bathtub caulk can be $2-3) and takes only about an hour if you take your time.
I had hoped to fully test this on a 2up 4day ride last weekend, but we had problems (see Clutch cable blues). But I do think that the tingly vibration has been reduced to more of a rumble. It's hard to quantify. I've only occasionally been bothered by the vibration on this bike, but under certain conditions, it can make my hands numb.
I think this mod helped. I had nothing to lose.