I received a PM asking a question that I think may benefit others. It really came down to clarification of some comments I made about the original right side bar and what was wrong. Here is a synopsis of my reply to clarify:
Q: The instructions tell me not to use my original nut on the rear mounting bolt and to thread it into the bar, but the bar is not threaded, DUH!
What they failed to tell you (at least in my instructions) is that the rear mounting bolt gets flipped around so that you insert it into the right side and it threads into the left side bar. The left bar is threaded and becomes the "nut" for the rear mounting bolt. Of course, if you start on the right side as they suggest, you can get confused by this easily... as I did. Anyway, remove the rear mounting bolt & nut, install the right side first and just slide the rear mounting bolt into the hole and through to the other side. When you install the left bar, your bolt will have threads to screw into.
Q: I received my crash bars but the right side appears to be about 1/8" short in the rear and won't allow the rear mounting bolt to line up.
My right side bar was not "short", it was just the right length (as I suspect yours is) it just would not slide far enough to the rear to make a clean opening for the bolt to go through. This was caused by clearance issues between the frame and the engine cover. As I said in the thread, I ground some metal off of each side (front & rear actually) to clearance the bar and make it fit. My replacement bar that just arrived had a smaller diameter tube used in the rear than my first one and the clearance was not an issue. (1.25" OD tubing on the original, 1.0" OD tubing on the replacement)
I hope this helps others that may have received the original version of the right side bar. An easy way to tell would be to check the diameter of the tubing used on the rear mounting point. If it is 1.25" OD, it is the original design and may have clearance issues on 09, 08, 07? but I suspect will fit an 06 since something minor changed from the original bike used to design the bars.