SW-Motech crash bar install problem - Kawasaki Versys Forum
 
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post #1 of 5 (permalink) Old 01-01-2012, 03:01 PM Thread Starter
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SW-Motech crash bar install problem

Man, nothing but problems this weekend. I'm installing the SW-Motech crash bars on my 2011. I've got everything in except the left side u-bolt. The bars don't seem to line up with the frame correctly, and I can't get the bolt into both holes. The U has to angle downward into the holes, and the bottom part won't even go in far enough to get the nut on the end of it. The right side U-bolt went in nearly horizontal, but the left side is way off. Have I got a defective bar, or am I missing something here? Also, what is the purpose of the U-bolt? Is it vital to have this secured, or is it just to keep the bars from vibrating against the frame? If I don't get this figured out today, I'd rather not have to completely undo everything I did, but I also don't want to be riding around if that piece absolutely needs to be secured..
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post #2 of 5 (permalink) Old 01-01-2012, 03:11 PM
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Did you just put the bolts in loosley or did you tighten everything as you went.?

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post #3 of 5 (permalink) Old 01-01-2012, 03:52 PM Thread Starter
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Originally Posted by weljo2001 View Post
Did you just put the bolts in loosley or did you tighten everything as you went.?
Tightened the two front mounts first, then the rear mount, right U-bolt, then left U-bolt. I tried backing out the front left bolt, but that didn't give me much play. It doesn't seem like a matter of wiggle room. The mounting points aren't loose enough to give much leeway, and the left U-bolt mount is way off. I did manage to put enough pressure on the bar to get the nuts on the bolt now, but it's putting a lot of pressure on the top of the frame bar, and it just doesn't look right...
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post #4 of 5 (permalink) Old 01-01-2012, 09:20 PM
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I had the same issue with mine i ended up using a small round file and taking a little bit out of the upper edge of the holes so the U-bolt could slip into them.. i dont have them tourqued up super tight just enough that they dont move.
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post #5 of 5 (permalink) Old 01-01-2012, 10:04 PM
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I just got a set of these, and had a similar issue, also on the left side. Sounds like a small manufacturing defect. But, mine seems to have been less severe than yours. I was able to thread the lower nut on a couple turns by hand, then ratcheted it down a bit. That pulled the U around lower, and the top of the U then lined up well.
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