ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: Curt on January 05, 2017, 03:22:03 PM
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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)
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Right side (outer)
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Right side (inner)
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Left side
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Thank you! This is valuable information.
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Excellent tutorial, thanks.
Sent from my XT1585 using Tapatalk
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After a few months, all the screws and bolts on my hand guards rusted. :(
(http://i.imgur.com/WxJqVPh.jpg)
(http://i.imgur.com/dBrZFd0.jpg)
(http://i.imgur.com/ijzT7DX.jpg)
(http://i.imgur.com/WYS0rT8.jpg)
(http://i.imgur.com/oC8WwZP.jpg)
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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
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All fasteners on my hand guards also rust like mad... The weatherproofing of the accesories is 'California Proof', I guess ;)
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When the rainy season started they were already completely rusted. These hand guards were NOT cheap.
Meh.
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I bought my guards directly from Cycra, using the parts listed here.
http://electricmotorcycleforum.com/boards/index.php?topic=5381.msg38545#msg38545
(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.
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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?
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Let's get those measurements to document for replacement! :)
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What's the difference between the Zero Cycra handguards and the non-Zero Cycra handguards? Is it just the logo?
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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.
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I confirmed before buying that the Zero version is custom bent to get around the front brake reservoir. Otherwise, they are identical. I was able to recreate the bend in my vice in about 5 minutes, ultimately saving some cash.
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My install of Cycra Ultra Handguards (the ones that really do not come in black... just black stickers). Koso heated grips and MFA generic windscreen. Last shot shows the tap done on the end of the handlebar to use the screw type connection instead of the clamps that come from Cycra.
(https://uploads.tapatalk-cdn.com/20170111/5acfe0b1bb3bb40521d9ee178e7f805b.jpg)
(https://uploads.tapatalk-cdn.com/20170111/d437d862c53698f072293b1dcce4ca06.jpg)
(https://uploads.tapatalk-cdn.com/20170111/aa3176d876daee46eed3e0755fc8af3f.jpg)
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Mounted mine today. Installed Givi HP1111, purchased from ebay for about €85. They perform very well on the first ride, no cold hands anymore!
Needed to install additional aluminium bar ends and to cut the rubber. About an hour work.
(https://dl.dropboxusercontent.com/u/14638644/Handguards.jpg)
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The cap screws provided by Cycra on my previous bike also rusted out. It's a real shame they don't come with stainless. Eight cost under $1.50. I replaced mine with stainless. Fortunately, at the time I had ordered 16, so I have a set for the Zero.
Here are the right ones:
M5X25 Socket Head Cap Screw FT Stainless Steel A2 DIN 912
http://www.mrmetric.com/M10628 (http://www.mrmetric.com/M10628)
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Mounted mine today. Installed Givi HP1111, purchased from ebay for about €85. They perform very well on the first ride, no cold hands anymore!
Needed to install additional aluminium bar ends and to cut the rubber. About an hour work.
(https://dl.dropboxusercontent.com/u/14638644/Handguards.jpg)
With that on the tip of your front fender? Some kind of reflector?
Sent from my Z981 using Tapatalk
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With that on the tip of your front fender? Some kind of reflector?
Dealer sticker unfortunately ;D
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I've updated the OEM handguard install section on the wiki, but stopped short of integrating the instructions here simply because they're organized differently, and I didn't want to try to merge them "blind". I definitely gathered as many references as seemed suitable.
http://zeromanual.com/index.php/Common_Modifications#OEM_Handguards (http://zeromanual.com/index.php/Common_Modifications#OEM_Handguards)
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I've updated the OEM handguard install section on the wiki, but stopped short of integrating the instructions here simply because they're organized differently, and I didn't want to try to merge them "blind". I definitely gathered as many references as seemed suitable.
http://zeromanual.com/index.php/Common_Modifications#OEM_Handguards (http://zeromanual.com/index.php/Common_Modifications#OEM_Handguards)
Cool, thanks Brian and thanks for the unofficial manual site.