Installing handguards


13 replies to this topic
  • jbird710

Posted January 26, 2007 - 07:22 PM

#1

This probably should be in the "General" fourm and I've searched for my question without finding an answer. I've been working on bikes for many years, but never installed handguards before. My question is how do you guys handle the throttle side? Is it necessary to cut off the end of the throttle tube to insert the expansion clamp in the end of the bars or is there some trick to do this without cutting the whole end off? Do you cut the ridge off of the end of the grip or just cut out a hole in the end of it?:ride: If you cut the entire end off of the throttle tube, wouldn't there be a problem with getting dirt between the tube and the bars? Are there any special tricks or best practice ways to install the guards?

Thanks in advance for any suggestions.

  • XR4DEZ

Posted January 26, 2007 - 08:10 PM

#2

Drill it out don't cut it off, that way you don't lose and length on the tube.

  • wheelnut46

Posted January 26, 2007 - 08:40 PM

#3

I just replaced a throttle tube recently. I soaked it in hot water to loosen the glue holding the end piece on, then just popped it off by pushing it onto the handlebar. The end cap popped right off.

  • tirebiter

Posted January 28, 2007 - 07:22 AM

#4

I use a "Unibit" and drill right thru the rubber & throttle tube till I get the desired hole size to fit the handguard keeper. If it looks like the rubber lip on the end of the throttle grip is going to cause trouble, I cut it off.
Then drill the clutch side grip, blow air thru the bars before installing the handguards.
Don't tighten anything till you have both handguards on.
Dunno what type of guards you getting, but be prepaired to do a little bending of the handguards, relocating of levers, throttle & other items clamped on the bars.

The main thing is DON'T tighten anything down till everything's in place, you'll see..
BTW, I've done dozens of handguard installations.

Unibits- Available at most mega hardware stores.
I use the fat one on the right.
Posted Image

  • jbird710

Posted January 28, 2007 - 08:56 AM

#5

Thanks for the info; I've got a set of uni-bits. The guard are from MSR and I've got the clutch side on. I do see where I need to bend the end of the guard that plugs into the bar just a bit to get it square. One other thing I was noticing is the piece that goes into the bars that's supposed to expand when you tighten the end screw doesn't expand enough to actually lock into the inside of the handlebar. These are stock bars and the guards are supposed to fit. Is this normal?

  • tirebiter

Posted January 28, 2007 - 10:44 AM

#6

Thanks for the info; I've got a set of uni-bits. The guard are from MSR and I've got the clutch side on. I do see where I need to bend the end of the guard that plugs into the bar just a bit to get it square. One other thing I was noticing is the piece that goes into the bars that's supposed to expand when you tighten the end screw doesn't expand enough to actually lock into the inside of the handlebar. These are stock bars and the guards are supposed to fit. Is this normal?


There's two sizes of expanding locks, one for thick aluminum bars (Smaller ID), and one for standard steel bars (Larger ID). The kit didn't come with both size lockers?? If not, sounds like you have the smaller ones.

If you purchased the guards at a dealer, they usually carry different size lockers. I know, it's Sunday..:ride:

Hey, when you bend the guard, don't grab it too close to the bar end hole, the last little bit of metal past the hole will snap right off- been there. :ride:

Update;
If you can't find the larger locks, shoot me a PM- just found a pair in my garage, I'd be happy to drop them in the mail, n/c..:ride:

They look like this-
Posted Image

  • jbird710

Posted January 28, 2007 - 01:48 PM

#7

Thanks for the info. I found some old Teflon shock bushings that work as perfect spaces with the smaller locks. Will know better next time. Broke out the 5 lb "Engineer's" hammer and got the guard to bend right in the vise.

Visit the ThumperTalk Store for the lowest prices on motorcycle / ATV parts and accessories - Guaranteed
  • jbird710

Posted January 28, 2007 - 06:40 PM

#8

Got 'em done. I installed a Works Connection Pro Perch w/ compression release for the clutch and put an aluminum throttle tube on also. Everything worked out great. The unibit allow me to make a perfect size hole in the aluminum tube; so the expansion insert fit through with just enough room to spare and it won't interfere with the throttle. The Teflon bushings actually seem to work pretty good with the smaller expansion pieces. A little bit of a pain to get the right size hole drilled; but seem solid. No interference with any of the levers. Didn't have to cut the ball ends off of the levers.
Thanks Tirebiter for the information!

  • tirebiter

Posted January 28, 2007 - 06:45 PM

#9

Glad to hear it all came together! :ride:

  • nick_j

Posted February 05, 2007 - 06:35 PM

#10

How do you ensure the right side guard doesn't interfere with the throttle? I just installed my first set on Saturday, and now the throttle won't close by itself. I haven't messed with it much since then, but before I go a-tinkering, I'm just wondering if there's something massively obvious I missed when I did the install..?

  • jbird710

Posted February 05, 2007 - 07:53 PM

#11

I had to bend the guard so it would be square with the end of the handlebars. This may be the problem that the grip is binding against the bar. Because I had the smaller inserts and I used a Teflon bushing in the end of the bars to fill in, I was able to cut the end of the grip and throttle tube so the insert barely cleared. The guard stands off about 1/8 of an inch from the end of the grip.

  • Ryan NJ

Posted June 26, 2007 - 09:52 AM

#12

Sooooo, you're actually supposed to bend them? My problem is getting them to reach on the clamp side when installing them on the Protaper big bars. this is the kit I'm using.

Posted Image

  • tirebiter

Posted June 26, 2007 - 07:28 PM

#13

Yep, most applications require a little bending to get them to fit.
Remember, there's a lot of different bars out there & they vary in length, sweep, angle, etc. It's a pain, but take your time..

  • evomx971

Posted June 27, 2007 - 12:35 PM

#14

Yep, bending is part of it. I use a piece of thick cardboard to protect the bars from the teeth of my vise.

I don't take any chances with the guard binding the throttle. I basically cut the end of the grip and tube completely off (I take as little material as possible). I then slide the throttle in so there's about 1/16-1/8 of bar showing between the twistgrip and the guard.





Related Content

Forums
Photo

Fell Off Trailer by usafxr


Dirt Bike   Make / Model Specific   Honda   XR600/650
  • Hot  43 replies
Forums
Photo
Supercross

Supercross Preview 2017 Part 1: Championship Contenders by Chris Cooksey


Dirt Bike   Special Interest Forums   Pro Racing
  • Hot  186 replies
Forums
Photo
Washington

Cle Elum Sunday 5/29: Looking for dual sport tips by TigerTanker


Dirt Bike   Dirt Bike Regional Discussion   Northwest
  • Hot  32 replies
Forums
Photo

93 xr650l Restoration Project by Zigster


Dirt Bike   Make / Model Specific   Honda   XR600/650
  • 17 replies
Wiki
Want to add a kickstart to your XR650L?  Here's how - last post by clc3251

Want to add a kickstart to your XR650L? Here's how


Articles
  • 1 reply
 
x

Join Our Community!

Even if you don't want to post, registered members get access to tools that make finding & following the good stuff easier.

If you enjoyed reading about "" here in the ThumperTalk archive, you'll LOVE our community. Come join ThumperTalk today!

The views and opinions expressed on this page are strictly those of the author, and have not been reviewed or approved by ThumperTalk.