Some background info in this post: https://honda250rally.wordpress.com/2021/08/11/handguard-info-warning/
- I have 30mm risers installed, so it gives me a little more room with the handguard mounts.
- The bars are stock bars.
Prepping the bars and grips
To mount the guards you first need to have access to the inside of the handlebar. On the clutch side it’s a simple matter of cutting the grip end off. Or alternatively you could just cut a hole on the rubber bar end to have access to the M6 hole inside the bars. If you are planning on drilling and tapping the M6 hole to an M8, which size bolts most handguards come with, you will naturally need a bit bigger hole.
I want to mount the handguards so that there is metal against metal, so I proceeded to cut the rubber grip end off.
As you can see below, the threaded insert is flush with the bars on the right side, but recessed on the left side. No idea why, but it seems they are made like this on purpose.
The throttle side is easier to do if you remove the grip first (how to is there -> https://honda250rally.wordpress.com/2021/08/11/handguard-info-warning/)
First I cut off the rubber grip end and the drilled the end off with a 22mm bit. Then I trimmed the rubber for another 6mm and used a belt sander to even the white plastic part with the rubber.
The method above is an unnecessarily complicated way of doing things and you could just as well take the grip off and go at it with a hacksaw.
I did not have spacers or washers that would be an exact fit for the inside diameter of the bars so I had to make a temporary solution with what I had at hand.
I wanted the handguards to tighten against the threaded insert and not the bar end, hence the use of washers. If you are fine with tightening the guards against the bars, you can forget hunting for suitable bushing or / washers.
The throttle side does not require any additional spacers as the insert is flush with the bar end.
THE ACERBIS X-FACTORY HANDGUARDS
LOOK AWAY NOW, and don’t do what I did.
I got real tired of messing with the handguards and just shortened the clutch lever to be done with them. I’m getting shorter/adjustable levers anyway later on, so this solution will do for now. Again not recommended and probably illegal somewhere in the world.
Some pics below on how the mounting hardware is setup on the bars.