Zeta handguards installation on TT250

flopsweat · 12-13-2021, 11:33 AM

So I made an attempt at installing the Zeta armor handguards that CSC sells, and ran into two issues I wanted to see if anyone has seen and solved. First, the oem levers on the bike just seem too long, as they will not fit within the guard frame, and the only way I have gotten it is to have the plug end that goes into the end of the grip sticking way out, meaning not flush with the grips. It's easier to see that the lever is not within the frame plane in the middle photo. Do people just buy new shorter levers, or is there something I'm missing?

Which goes into my second issue, whenever I tighten the throttle side grip screw that has the pressure fit inside, it makes the throttle bind up and it won't freely snap back to zero. Do I just need to cut off more of the grip? I only made the hole flush with the bar inside.

TxTaoRider · 12-13-2021, 01:10 PM

You might try loosing the throttle clamp and slide it inwards about 1/8" to free up the throttle action.

flopsweat · 12-13-2021, 03:12 PM

After seeing some more videos, I think as far as the sticking throttle goes it looks like I might just need to trim off more of the grip and throttle tube. I started quite conservatively with the chopping.

flopsweat · 12-15-2021, 07:49 AM

Just spoke with a tech at CSC, as well as MFR Offroad Rider on the 'tube, and both said they just chop off the end of the lever. Easy enough, I've got a grinder at work that can make short and neat work of that.

**JerryHawk250** · 12-15-2021, 08:41 AM

Buy shorter adjustable levers. You can find complete universal sets on Ebay and Amazon fairly cheap.

flopsweat · 12-27-2021, 08:26 AM

Works for now! 5 minutes with the dremel on the lever knobs, and just took off a bit more of the throttle grip/sleeve to eliminate the binding I was getting before.

12-13-2021, 11:33 AM	#1
flopsweat Join Date: Oct 2021 Location: The burbs of Chicago Posts: 237	Zeta handguards installation on TT250 So I made an attempt at installing the Zeta armor handguards that CSC sells, and ran into two issues I wanted to see if anyone has seen and solved. First, the oem levers on the bike just seem too long, as they will not fit within the guard frame, and the only way I have gotten it is to have the plug end that goes into the end of the grip sticking way out, meaning not flush with the grips. It's easier to see that the lever is not within the frame plane in the middle photo. Do people just buy new shorter levers, or is there something I'm missing? Which goes into my second issue, whenever I tighten the throttle side grip screw that has the pressure fit inside, it makes the throttle bind up and it won't freely snap back to zero. Do I just need to cut off more of the grip? I only made the hole flush with the bar inside.
	2

12-13-2021, 01:10 PM	#2
TxTaoRider Join Date: Oct 2020 Location: Flower Mound Texas Posts: 904	You might try loosing the throttle clamp and slide it inwards about 1/8" to free up the throttle action. __________________ 2021 Tao Tbr7 - "Lucille" Mods so far- Brozz swingarm, 21" front rim (Bridgestone Tw302 rear/Dunlop D606 front tires), Digital gauge cluster, pz30b pumper carb, after market hand guards, aftermarket brake and clutch levers, round fold away mirrors, Fly handlebars shortened slightly, 13t front sprocket 2009 Q-link Legacy 250 1982 Suzuki GS1100ES - "Jolene"
	1

12-13-2021, 03:12 PM	#3
flopsweat Join Date: Oct 2021 Location: The burbs of Chicago Posts: 237	After seeing some more videos, I think as far as the sticking throttle goes it looks like I might just need to trim off more of the grip and throttle tube. I started quite conservatively with the chopping.
	0

12-15-2021, 07:49 AM	#4
flopsweat Join Date: Oct 2021 Location: The burbs of Chicago Posts: 237	Just spoke with a tech at CSC, as well as MFR Offroad Rider on the 'tube, and both said they just chop off the end of the lever. Easy enough, I've got a grinder at work that can make short and neat work of that.
	0

12-27-2021, 08:26 AM	#6
flopsweat Join Date: Oct 2021 Location: The burbs of Chicago Posts: 237	Works for now! 5 minutes with the dremel on the lever knobs, and just took off a bit more of the throttle grip/sleeve to eliminate the binding I was getting before.
	1