02-04-2016, 09:29 PM | #1 |
Join Date: Oct 2015
Location: FL, GA, NC
Posts: 771
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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: 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
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2016 Honda CB500F......2017 Triumph Street Twin 2014 XT 250........ Last edited by jbfla; 02-04-2016 at 09:46 PM. Reason: add pic |
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02-04-2016, 09:40 PM | #2 |
Join Date: Dec 2014
Location: Deerfield Beach FL
Posts: 1,410
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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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02-04-2016, 10:02 PM | #3 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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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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Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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02-04-2016, 11:42 PM | #4 | |
Join Date: Oct 2015
Location: FL, GA, NC
Posts: 771
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Quote:
Thanks for the explanation. jb
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2016 Honda CB500F......2017 Triumph Street Twin 2014 XT 250........ |
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02-05-2016, 12:36 AM | #5 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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You're welcome.
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Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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02-05-2016, 01:01 AM | #6 |
Join Date: May 2007
Location: Warshington
Posts: 928
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So JB do you want to sell the Enduro Engineering guards from Rocky Mtn ATV? rj
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02-05-2016, 08:10 AM | #7 | |
Join Date: Oct 2015
Location: FL, GA, NC
Posts: 771
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Quote:
jb
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2016 Honda CB500F......2017 Triumph Street Twin 2014 XT 250........ |
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02-05-2016, 11:54 AM | #8 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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JB, that's an excellent write-up, with terrific pics. Nice work.
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02-05-2016, 01:38 PM | #9 |
Join Date: May 2007
Location: Warshington
Posts: 928
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