Tusk D-Flex and Clutch Cable Clearance on Pro Taper Hi-ATV
Close
    
    
Page 1 of 2 12 LastLast
Results 1 to 10 of 15
Like Tree8Likes

Thread: Tusk D-Flex and Clutch Cable Clearance on Pro Taper Hi-ATV

  1. #1
    Senior Member retmotor's Avatar
    Join Date
    Dec 2011
    Location
    The Southwest
    Posts
    535
    I decided to put on the Pro-Taper High ATV bars, new grips, grip heaters, and the Tusk D-Flex hand guards and it seems like it has been one problem after another. Currently, the problem I cannot solve is a clearance issue between the clutch cable and the hand guard. In order to have the clutch lever at a comfortable position, the bar mount bracket for the hand guard wants to mount exactly in line with where the cable enters the clutch lever housing. If I move the bracket over the cable, the hand guard is pointing towards the sky. If I move it under the cable, the hand guard is pointing toward the ground. (I'm exaggerating a bit, but you get the idea.) It seems to me this cannot be a problem unique to the TW and this bar configuration. If the guard is designed to protect the lever, it needs to be on the same plane as the lever, give or take. If it's on the same plane as the lever, the clutch cable is going to right where the bar mount bracket needs to be.



    You that have this set-up, how'd you overcome this issue?
    2012 TW200: Cyclerack Rear Rack ... Cyclerack Bag Supports ... Jimbo Cafe Shield ... Pro-Taper ATV High Bars ... Tusk D'Flex Hand Guards ... Tusk Hand Mitts ... Tusk Grip Heaters

  2. #2
    Senior Member Wingnut's Avatar
    Join Date
    Aug 2012
    Location
    Salty City, Utah
    Posts
    434
    I had fit problems with mine as well, I do not have those bars, and I had problems on the brake side not the clutch side. I solved mine by mounting in a different location and actually bending the right side into a steeper angle closed. I will get some pic's tomorrow.

  3. #3
    Senior Member PalmStateCrawler's Avatar
    Join Date
    Aug 2011
    Location
    Cayce, SC
    Posts
    3,109
    Place the mount right under the crossbar.
    '13 690 Enduro R too many frickin farkles...
    '07 KLX250 farkled (wife's bike)
    '86 BW80 farkled to size
    '10 TW200 you will be missed

  4. Remove Advertisements
    TW200Forum.com
    Advertisements
     

  5. #4
    Senior Member retmotor's Avatar
    Join Date
    Dec 2011
    Location
    The Southwest
    Posts
    535
    Quote Originally Posted by Wingnut View Post
    I had fit problems with mine as well, I do not have those bars, and I had problems on the brake side not the clutch side. I solved mine by mounting in a different location and actually bending the right side into a steeper angle closed. I will get some pic's tomorrow.
    Thank you. I'm having trouble picturing how you did that.



    Quote Originally Posted by PalmStateCrawler View Post
    Place the mount right under the crossbar.
    It doesn't even come close to reaching under the crossbar mount. I'll fiddle with it and see if there's a way to make it reach short of trimming the bars. Actually, trimming the bars might be what I'll have to do. That'll kind of suck -- I just got the grip heaters on there.
    2012 TW200: Cyclerack Rear Rack ... Cyclerack Bag Supports ... Jimbo Cafe Shield ... Pro-Taper ATV High Bars ... Tusk D'Flex Hand Guards ... Tusk Hand Mitts ... Tusk Grip Heaters

  6. #5
    Senior Member Ayers Garage's Avatar
    Join Date
    Jun 2012
    Posts
    125
    I have the same bars and same handguards and also had the issue you're describing. I wound up setting the clutch angle to where I liked it and installing the guards beneath the cable, but pushed up to the cable as much as possible to keep the handguards at a reasonable tilt.



    These pics aren't the best.







    By the way, a paper towel and some acetone will make those handguards go from this...





    to this....(no logo anymore)

    TrailWaysAW and JagLite like this.

  7. #6
    Senior Member retmotor's Avatar
    Join Date
    Dec 2011
    Location
    The Southwest
    Posts
    535
    Quote Originally Posted by PalmStateCrawler View Post
    Place the mount right under the crossbar.
    Dear PSC, I think I might love you.



    Well, strong like.



    Well, think fondly of...



    Anyhow, I figured out a trick to get these things on under the crossbar. As it was, I couldn't get the bar bracket of the hand guard to within a 1/2" of the slot on the hand guard and that was putting some muscle behind it. Then I realized the bar geometry would be different if I installed the hand guard underneath the bar and then rotated up and into position. Because of the bend of the bar, it would bolt together on the bottom of the bar and with a little force, not too much I hope, I was able to rotate it up and into position. Easiest thing ever. So, thanks is not enough, but given our geographic proximity, it's all I got. Thanks.





    Quote Originally Posted by Ayers Garage View Post
    ...

    By the way, a paper towel and some acetone will make those handguards go from this ... to this....(no logo anymore)
    Thanks, AG. You saved yourself from reading another, "I'm a dumbass" thread by "retmotor" asking that very question
    TrailWaysAW and JagLite like this.
    2012 TW200: Cyclerack Rear Rack ... Cyclerack Bag Supports ... Jimbo Cafe Shield ... Pro-Taper ATV High Bars ... Tusk D'Flex Hand Guards ... Tusk Hand Mitts ... Tusk Grip Heaters

  8. #7
    Senior Member PalmStateCrawler's Avatar
    Join Date
    Aug 2011
    Location
    Cayce, SC
    Posts
    3,109
    No problem. I've heard alot of issues about this protaper vs handguards fitment. You aren't the only one that had this issue and hope others with this problem will read this and find how easy it is to attach them. Putting the mount under the crossbar also allows more room other handlebar attached farkles. Ride on!
    JagLite likes this.
    '13 690 Enduro R too many frickin farkles...
    '07 KLX250 farkled (wife's bike)
    '86 BW80 farkled to size
    '10 TW200 you will be missed

  9. #8
    Senior Member frog13's Avatar
    Join Date
    Jun 2011
    Location
    SW, Ohio
    Posts
    2,486
    So,with OEM handlebars,will the D-Flex guards work WITHOUT modifying anything?......such as;cutting off the "ball-end" of the front brake & clutch levers or bending the D-Flex bar itself just so it will fit?. TIA

  10. #9
    Member mikesova's Avatar
    Join Date
    Mar 2013
    Location
    Gladwin, MI
    Posts
    54
    Quote Originally Posted by frog13 View Post
    So,with OEM handlebars,will the D-Flex guards work WITHOUT modifying anything?......such as;cutting off the "ball-end" of the front brake & clutch levers or bending the D-Flex bar itself just so it will fit?. TIA


    Yeah, I put them on my wife's bike and they fit fine. However, be prepared to loosen stuff on the bars and move them around to achieve the best fit.



    Edit: you do need to cut the ends off the grips and cut the end off the throttle tube(tubing cutter is awesome for this), but at this stage I was assuming that was a given.
    TrailWaysAW likes this.

  11. #10
    Senior Member jontow's Avatar
    Join Date
    Oct 2010
    Location
    Potsdam, NY
    Posts
    701
    Stock bars and Tusk D-Flex guards here. They fit fine, and I used the same trick of mounting under the crossbar.



    TrailWaysAW likes this.
    --

    1997 TW, well loved, a bit modified.

Page 1 of 2 12 LastLast

Sponosred Links

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  

Similar Threads

  1. Tusk D-Flex Handguard Installation
    By SpudRider in forum General Discussion
    Replies: 17
    Last Post: 03-07-2017, 08:31 AM
  2. Replies: 2
    Last Post: 05-28-2013, 11:00 AM
  3. SOLD Tusk D-Flex Handguards For Sale
    By JRD in forum TW200 Classifieds
    Replies: 3
    Last Post: 02-28-2013, 01:44 PM
  4. Clutch Cable Measurement?
    By SpudRider in forum Technical Help
    Replies: 8
    Last Post: 08-06-2012, 11:21 PM
  5. New clutch cable = NICE!
    By darnold87 in forum Technical Help
    Replies: 6
    Last Post: 08-05-2012, 08:50 PM

Search tags for this page

installing tusk handguards on protaper bars

,

pro taper handguards problems

,

protaper clutch cable

,

ram handguard for a clutch

,

tusk d flex handguards on yamaha tw200

,

tusk d-flex logo

,

tusk dflex hamdguards clearance

,

tw200 handguards

,

tw200 pro-taper atv high bars

Click on a term to search for related topics.