No clearance with handguards (lever hits)

5 replies to this topic
  • Redwoods

Posted April 16, 2004 - 10:00 AM


I just bought some tusk d-flex handguards and the clutch lever hits the metal bar, so I moved it down and it hits the plastic, there is not enough clearance for the clutch lever to be operated without touching the guard. Any suggestions?

  • simon@vic

Posted April 16, 2004 - 10:04 AM


maby move the clutch perch in a bit :)

  • mtrablue

Posted April 17, 2004 - 03:37 AM


cut the ball off the end of the lever. if your uncomfortable with the look or feel you can bend the end up a little without it breaking off. the new wr's have a different lever from the yz's so finding a shortie will be tough. some catalogs list them as the same but there not. or go z-start.

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  • tp3dxf

Posted April 17, 2004 - 11:15 AM


You might want to look into getting a MSR Raptor clutch lever set up. It has an adjustable pull. Makes the clutch pull lighter or harder if you like, and it has a cool shorty lever with a built in rubber gripper. They are fairly inexpensive as well. About $40 for the whole set up.

  • trailriderjoe

Posted April 18, 2004 - 01:12 AM


I had the same problem with my Bark busters. I had to "Tweek" the bark busters in the vise until everything fit. Still to this day when the weather is really HOT, the clutch levers ball end gets a little sticky on the bark buster (it's really close). The other thing I do is rotate my levers / perches down just under the guard. Food for thought :)

  • Redwoods

Posted April 19, 2004 - 04:35 AM


Thanks, I talked to a mechanic friend of mine and he suggested I move the lever on the bars more to the inside. I did and it worked. It now has clearance. Thanks for the posts.


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