Tusk Bar Ends Model 209115 Instruction Manual

1. Introduction

These Tusk Bar Ends are designed to provide protection for your motorcycle's grips and handlebars. They are engineered for straightforward installation and compatibility with most standard handlebars, offering a durable barrier against impacts and abrasions.

2. Safety Information

Always prioritize safety during installation and use. Read all instructions carefully before proceeding.

• Ensure the motorcycle is stable and securely supported before beginning any work.
• Wear appropriate personal protective equipment, such as safety glasses and gloves.
• Do not overtighten fasteners, as this can damage components. Refer to specific torque specifications if available for your handlebar.
• If you are unsure about any installation step, consult a qualified motorcycle mechanic.
• Verify that all components are securely fastened and do not interfere with the operation of controls (throttle, brakes) before riding.

3. Package Contents

Please verify that all the following components are included in your package:

• Two (2) Tusk Bar Ends (Orange)
• Two (2) Mounting Screws
• Multiple sets of rubber sleeves/bushings (various sizes for different handlebar inner diameters)

Image: All components included in the Tusk Bar Ends package. This includes the two orange bar ends, two mounting screws, and a selection of rubber sleeves of different sizes to ensure compatibility with various handlebar inner diameters.

4. Setup and Installation

Follow these steps to properly install your Tusk Bar Ends:

1. Prepare Handlebar: Ensure the ends of your motorcycle handlebars are clear of any debris or obstructions. If existing bar ends are present, remove them.
2. Select Rubber Sleeve: Choose the appropriate rubber sleeve size that fits snugly into the inner diameter of your handlebar. Test different sizes until you find the best fit.
3. Assemble Bar End: Insert one of the mounting screws through the center of a Tusk Bar End. Then, slide the selected rubber sleeve onto the screw, ensuring it sits flush against the back of the bar end.
4. Insert into Handlebar: Carefully insert the assembled bar end into the open end of your handlebar.
5. Tighten Screw: Using an appropriate hex key or screwdriver, slowly tighten the mounting screw. As you tighten, the rubber sleeve will expand, securing the bar end firmly within the handlebar. Do not overtighten.
6. Repeat for Other Side: Perform the same steps for the other handlebar end.
7. Final Check: Gently pull on both bar ends to ensure they are securely fastened and do not rotate or slide. Confirm that they do not impede the movement of the throttle or brake levers.

Image: A Tusk Bar End securely installed on a motorcycle handlebar, demonstrating the final appearance and fit.

5. Operating

Once properly installed, the Tusk Bar Ends require no specific operational procedures. They function passively to protect the ends of your handlebars and grips during normal use and in the event of a fall or impact.

6. Maintenance

To ensure the longevity and effectiveness of your Tusk Bar Ends, perform the following maintenance:

• Regular Inspection: Periodically check the bar ends for any signs of damage, cracks, or excessive wear.
• Tightness Check: Ensure the mounting screws remain tight. If they feel loose, gently tighten them. Avoid overtightening.
• Cleaning: Clean the bar ends with a mild soap and water solution. Avoid harsh chemicals that may damage the finish.
• Replacement: If a bar end becomes significantly damaged, replace it to maintain optimal protection for your handlebars.

7. Troubleshooting

Common issues and their solutions:

• Bar End is Loose:
  Solution: Ensure you have selected the correct size rubber sleeve for your handlebar's inner diameter. Tighten the mounting screw until the bar end is secure. If it continues to loosen, the rubber sleeve may be worn or incorrectly sized.
• Bar End Does Not Fit into Handlebar:
  Solution: Verify that the chosen rubber sleeve is not too large for the handlebar's inner diameter. Check for any internal obstructions within the handlebar that might prevent insertion.
• Bar End Scratched/Damaged:
  Solution: While designed for protection, severe impacts can damage the bar ends. If cosmetic or structural damage occurs, consider replacing the bar end to maintain aesthetic appeal and protective function.

8. Specifications

9. Warranty and Support

For specific warranty information, technical assistance, or to inquire about replacement parts, please refer to the official TUSK website or contact TUSK customer service directly. You can often find support resources and contact details on the manufacturer's official product pages or their dedicated support section.

Visit the official TUSK Store for more information: TUSK Powersports Store