Adventures with Wrap Around Handguards
I wanted handguards on my RX3 to protect my old hands from wind and rain and snow and sleet...
So I bought these Enduro Engineering guards from Rocky Mtn ATV: http://i42.photobucket.com/albums/e3...ps9pnikqp1.jpg The installation was easy, and they worked to block the wind, but I wasn't completely satisfied that they did not wrap around to the end of the handlebars. Then I read Woodlandsprite's thread to learn from others. http://www.chinariders.net/showthread.php?t=14766 Spudrider – Tusk D-Flex Handguards -changed brake master cylinder -tapped inside of handlebars to 1/2” and used bolts -cut off end of throttle side hand grip -cut off ends of brake and clutch levers Woodlandsprite – Barkbuster VPS Handguards -12 mm insert fit inside bars without drilling -did not cut brake or clutch levers -used spacers between bar ends and handguard backbone mount Huck369 – ebay handguards, like this: http://www.amazon.com/TDH-Aluminium-...rds=handguards -fit without drilling handlebars, and have spacers for different size bars -cut ends of brake and clutch levers Riceburner – G2 Competition Handguards and MSR Deflector Shields -used spacers on end of handlebars -did not cut levers If I had known all this beforehand, I think I would have chosen Huck369's solution. But I had already purchased the Tusk D-Flex handguards, 1 1/8' adapter, and the spoilers. https://www.rockymountainatvmc.com/p...lex-Handguards So how hard could it be? Put the inserts in the bar ends, and mount the clamps on the handlebars. http://i42.photobucket.com/albums/e3...psjibpmfvu.jpg I even watched Rocky Mtn. ATV's installation video: https://www.youtube.com/watch?v=nxscje3HwmU Here's what happened: I drilled the ends of the handgrips with a 7/8” hole saw: (I wanted the inserts to rest firmly against the metal bar ends) http://i42.photobucket.com/albums/e3...pshwy9nu46.jpg The inserts wouldn't fit inside the bars, so I first drilled them with a 1/2” bit, but they still didn't fit so I used a 9/16” bit. http://i42.photobucket.com/albums/e3...pslcidszfc.jpg The insert fit nicely inside the handlebar. But the insert flange rubbed against the throttle tube, and I did not want to cut off the end of the grip as shown in the installation video. I removed the throttle tube, and filed the inside end of the tube so it moved freely around the insert flange: http://i42.photobucket.com/albums/e3...pshflcopxp.jpg Now for the handlebar clamps. The 1 1/8” adapters didn't fit: http://i42.photobucket.com/albums/e3...psjzwfygxp.jpg And the 7/8” clamps didn't fit. No one had mentioned this before.....and where did all those metal shavings come from? http://i42.photobucket.com/albums/e3...psggmthqfv.jpg This took the longest amount of time of the entire installation...filing, grinding, test fitting...filing, grinding, test fitting... until the clamps fit around the handlebars: http://i42.photobucket.com/albums/e3...psq46rtlt2.jpg Mounted the clamps, and attached the handguard backbone, and used some ss washers as spacers on the bar ends. It all fit: http://i42.photobucket.com/albums/e3...pssuznar49.jpg Next was the clutch side...should be easy.... It was easier...drilled the handlebars, installed inserts, filed and ground clamps to fit. But then decided to re-route the clutch cable when the bend around the clamp was too severe: http://i42.photobucket.com/albums/e3...psqjg9etas.jpg All that was left was to cut the lever ends (smoothed and rounded the cut ends with a bench grinder), and to reinstall them. (I emailed Ryan at CSC to ask about the availability of “shorty” levers. He replied at this time (Feb. 2016), they have been unable to find any that will fit the RX3.) http://i42.photobucket.com/albums/e3...psdzarswje.jpg Then stepped back to admire my handiwork..........oh! There was one more thing. I accidentally cross threaded one of the screws for the spoilers...and had to re-tap: http://i42.photobucket.com/albums/e3...psyuw9cyql.jpg Now, I hope I didn't forget anything else... http://i42.photobucket.com/albums/e3...ps9vrqovxj.jpg http://i42.photobucket.com/albums/e3...ps9hk9knuf.jpg jb |
Very cool. I would think CSC would be all about getting a custom hand guard kit put together for the RX3. Seems to be a very popular mod.
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Thanks for posting this detailed installation with excellent photographs, JB. :)
I used the standard handlebar adapters to mount my Tusk D-Flex hand guards. I trimmed the hand guards to a shorter length, and mounted the adapters closer to the end of the handlebars. ;) |
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Thanks for the explanation. jb |
You're welcome. :)
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So JB do you want to sell the Enduro Engineering guards from Rocky Mtn ATV? rj
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jb |
JB, that's an excellent write-up, with terrific pics. Nice work.
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