I'll describe my experience installing the official Zero Cycra handguard accessory ($170) on a Zero FX. No instructions came with it, and tolerances are a bit tight.
Zero FX Cycra Handguard Installation
Preparation:
- Review pictures (below)
- Remove rubber bar ends
- Loosen the brake lever assembly by exactly one turn per Allen screw
- Slide brake lever assembly left by 1/2" to 1"
Right handguard rail assembly:
- Find right handguard rail
- Insert long Allen head bar-end screw into rail
- Thread thin spacer washer onto screw
- Thread long expanding aluminum cylinder onto screw
- Thread aluminum wedge onto screw
- Tighten screw hand tight with Allen wrench
- Slide rail assembly into end of bar
- Hold handguard rail at approximately the correct height
- Further tighten the screw. This expands the cylinder enough
to hold the the rail roughly in place
Right handguard clamp assembly:
- Find right clamp, engraved with a big "R"
- Arrange clamp on bar with the four Allen bolts,
- Tighten just enough to hold the clamp in place
- Place thick spacer between clamp and handguard rail
- Insert long hex bolt through rail, spacer and into clamp
- Begin to thread it, but don't tighten yet
Right handguard position adjustment and tightening:
- The handguard rail should be slightly higher than the end of the brake lever
- Monitor the handguard height during the tightening process
- Tighten so everything is square as possible and with stress minimized
- Make sure wires and cables are not pinched or stressed
- Tighten bar-end screw
- Tighten large hex bolt
- Tighten small clamp bolts evenly, going round in a circle and making
sure the open spaces at the top and bottom of the clamp are equal
- Tighten brake lever assembly, which should be about one turn per Allen screw
Left handguard:
- Repeat for the left side the same as right,
easier than the right side because there is no lever to move
- Make sure the handguard height is identical to the right side
(I measured for equal height above the turn signals)
Inspection:
- IMPORTANT: there should be a narrow but consistent clearance of about
1/4" between the end of the brake lever and the rail
- The lever and mirror should be rotated to the right position
- There should also be about 1/4" of clearance between the clamp and
brake line banjo bolt
- MOST IMPORTANT: the thin spacer guarantees the throttle cannot bind AT ALL,
regardless of how tight the end screw is... VERIFY THIS IS THE CASE!
Finish:
- Affix plastic handguards (3 screws and washers each)
- Affix rail edge guards (2 screws each)
- Save rubber bar ends and short expanding aluminum cylinders (unused)