Adventures with Wrap Around Handguards

[jbfla]

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:



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.


I even watched Rocky Mtn. ATV's installation video:




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)




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.




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:




Now for the handlebar clamps.

The 1 1/8” adapters didn't fit:



And the 7/8” clamps didn't fit.

No one had mentioned this before.....and where did all those metal shavings come from?




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:



Mounted the clamps, and attached the handguard backbone, and used some ss washers as spacers on the bar ends.

It all fit:




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:




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.)



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:




Now, I hope I didn't forget anything else...





jb