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When installing the throttle side guard do I need to drill the plastic out to the size of the handle bar and do I need to cut the grip off even with the handle bar? Or??
 

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If a bolt goes into the bar end, then yes you will have to cut both.

Somebody on here posted a nice method where they put a zip-tie around the grip and used it as a cutting guide to make a nice clean cut of the hand grip.
 

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This is what I did when I put on my Oxford adventure heated grips.
 

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Yes... the throttle tube and grip need to be opened up enough to rotate freely over the handle bar and not be restricted by the bar-end mounting of the hand guards.
 

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Only cut the grip and plastic with the hack saw. Leave the metal handle bars whole.
 
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