Barkbusters VPS Black Handguard (BB.BHG15-1.BK) Instruction Manual for 7/8" Handlebars

1. Introduction

This manual provides comprehensive instructions for the installation, operation, and maintenance of the Barkbusters VPS Black Handguard (BB.BHG15-1.BK). These full-wrap handguards offer robust protection against obstacles and moderate weather, designed for motorcycles with 7/8" handlebars and long brake/clutch levers, suitable for street and adventure-touring bikes.

Key Features:

• Universal fit for many Trail, Enduro, Dual Sport, and Adventure bikes with 22mm (7/8") handlebars.
• Full-wrap design for enhanced protection.
• Designed to accommodate long brake and clutch levers.
• Provides protection against obstacles and moderate weather conditions.

2. Package Contents

Verify that all components are present before beginning installation. The complete kit includes:

• 2 x VPS Black Handguard Frames (Left and Right)
• 2 x Handlebar Mounting Clamps
• 2 x Bar End Weights/Bushings
• All necessary mounting hardware (bolts, washers, nuts)

Figure 1: Complete Barkbusters VPS Black Handguard kit showing all components.

Figure 2: Close-up view of the handguard frames and bar end components.

3. Safety Information

Always prioritize safety when working on your motorcycle. Improper installation or use of this product can lead to serious injury or damage. Read all instructions carefully before installation.

• Ensure the motorcycle is stable and secure before beginning work.
• Wear appropriate personal protective equipment (PPE), such as gloves and eye protection.
• Do not overtighten fasteners; refer to your motorcycle's service manual for torque specifications if available.
• Ensure handguards do not interfere with the operation of brake, clutch, or throttle controls.
• Regularly inspect handguards for damage or loose fasteners.

4. Setup and Installation

The Barkbusters VPS Black Handguards are designed for straightforward installation on 7/8" handlebars. Follow these steps carefully:

1. Prepare the Handlebars: Remove any existing bar ends or handguards. Ensure the handlebar ends are clear and free of obstructions.
2. Assemble Handguard Components: Attach the plastic VPS guards to the aluminum frames using the provided screws.
3. Install Bar End Mounts: Insert the bar end weights/bushings into the ends of your handlebars. Secure them using the appropriate bolts, ensuring a snug fit without over-tightening.
4. Attach Handlebar Clamps: Position the handlebar mounting clamps on the handlebar, ensuring they are clear of other controls (brake master cylinder, clutch perch, throttle housing). Loosely secure the clamps.
5. Connect Handguard Frames: Attach the inner end of the handguard frames to the handlebar clamps. Loosely secure all bolts.
6. Adjust Position: Adjust the angle and position of the handguards to ensure they do not interfere with lever operation or full steering lock. Ensure adequate clearance for all controls.
7. Tighten All Fasteners: Once satisfied with the position, progressively tighten all bolts, starting from the bar ends and then the handlebar clamps. Do not overtighten.
8. Final Check: Operate the brake, clutch, and throttle. Turn the handlebars from lock to lock to confirm no interference.

5. Operating Instructions

Once properly installed, the Barkbusters VPS Black Handguards operate passively by providing a physical barrier. They are designed to:

• Protect Hands: Shield your hands from impacts with branches, debris, and other obstacles during riding.
• Protect Levers: Guard brake and clutch levers from damage in the event of a fall or impact.
• Weather Protection: Offer moderate protection against wind, rain, and cold, enhancing rider comfort.

No specific operational adjustments are required after installation, beyond ensuring they remain securely fastened and do not impede controls.

6. Maintenance

Regular maintenance ensures the longevity and effectiveness of your handguards:

• Cleaning: Clean the handguards regularly with mild soap and water to remove dirt, mud, and grime. Avoid harsh chemicals that may damage the plastic or finish.
• Inspection: Periodically check all mounting bolts and fasteners for tightness. Re-tighten if necessary. Inspect the aluminum frames and plastic guards for any signs of damage, cracks, or wear. Replace damaged components immediately.
• Corrosion Prevention: If riding in wet or corrosive environments, apply a suitable anti-corrosion spray to metal components.

7. Troubleshooting

Below are common issues and their potential solutions:

• Issue: Handguards do not fit 7/8" handlebars.
  Solution: While designed for 7/8" handlebars, some variations in handlebar dimensions or existing controls may require minor adjustments or alternative mounting solutions. Ensure all existing bar-end weights or internal handlebar components are removed. If issues persist, consult a professional mechanic or the manufacturer.
• Issue: Handguards interfere with brake/clutch levers or throttle.
  Solution: Loosen all mounting bolts and carefully reposition the handguards and clamps. Ensure sufficient clearance for full lever travel and throttle rotation. Re-tighten all fasteners once proper clearance is achieved.
• Issue: Handguards feel loose after installation.
  Solution: Re-check all mounting bolts for proper tightness. Ensure the bar end weights/bushings are securely seated within the handlebar. If the issue persists, inspect components for damage or wear.
• Issue: Missing components from the kit.
  Solution: Refer to the "Package Contents" section and contact the retailer or manufacturer with your purchase details to request missing parts.

8. Specifications

9. Warranty and Support

For warranty information, product support, or to purchase replacement parts, please contact the manufacturer, Barkbusters, or your authorized retailer. Keep your proof of purchase for warranty claims.