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[Curt]

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)

[Curt]

Right side (outer)

[Curt]

Right side (inner)

[Curt]

Left side

[BertTrack]

Thank you! This is valuable information.

[odedmaz]

Excellent tutorial, thanks.

Sent from my XT1585 using Tapatalk

[MajorMajor]

After a few months, all the screws and bolts on my hand guards rusted.

[clay.leihy]

Curt, thank you! Awesome write up. Needs to be in the manual. (It showed me what is wrong with mine, which came installed and were missing the thin spacers.)

MajorMajor, only the Allen screws that hold the clamps rusted on mine. I picked up some nice stainless ones at Lowe's.

Sent from my Z981 using Tapatalk

[Skidz]

All fasteners on my hand guards also rust like mad... The weatherproofing of the accesories is 'California Proof', I guess

[MajorMajor]

When the rainy season started they were already completely rusted. These hand guards were NOT cheap.
Meh.

[acacia1731]

I bought my guards directly from Cycra, using the parts listed here.
http://electricmotorcycleforum.com/boards/index.php?topic=5381.msg38545#msg38545

They've worked well for a year now.  Some rust is showing inside the hex recesses of the chrome bolts (two pairs holding the handlebar clamps), but the Phillips screws are still clean and black.  It's been washed/wet about 6 times but garage kept otherwise.

[MajorMajor]

If by "chrome bolts" you mean the bolts that go into the handle bars, those are beginning to rust as well but not as bad as the rest of the screws. There is some rust on the inner part of the hex.

I will be looking at replacing all the bolts ASAP as I'm worried they will be too hard to remove if they continue to rust.

Does anyone happen to have the measurements for all the bolts?

[BrianTRice@gmail.com]

Let's get those measurements to document for replacement!


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[andrews]

What's the difference between the Zero Cycra handguards and the non-Zero Cycra handguards? Is it just the logo?


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[MajorMajor]

A bit tongue in cheek, the Zero version rusts like crazy.

Seriously though, they appear to be custom bent to fit the brake lever on Zero + the logo.