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Discussion Starter #1
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?
 

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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.
 

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Discussion Starter #4
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.



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.
 

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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)

 

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Discussion Starter #6
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.





...

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
 

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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!
 

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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
 

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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.
 

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To remove the Dflex logo, I tried scrubbing with acetone based nail Polish remover and a scotch Brite pad...no luck. Any other ideas before I paint over them? They must use a different printingredients method or something now.
 

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Nail polish remover based on acetone is very mild compared to actual acetone. Acetone will melt those plastics guards if you let them soak in it. I'd try 100% acetone. I'd bet they are either abs or PVC, both of which will be affected by direct contact with acetone.
 

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Tusk Pro Handguards DO NOT fit with the pro taper atv high bars. the updated handguard adapter does not have the piece that pivots in it and will not work under the pro taper cross bar. Kind of surprised at the fit issues as it seems pro taper high atv bars are highly recommended here. would not go down this road again and would definatley go with different bars next time (or a riser).
 
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