Highway Dirt Bike (HDB) top clamp and handguards

Discussion in 'Equipment' started by Chadx, Jan 23, 2010.

  1. DiscoDino

    DiscoDino Long timer

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    Looks awesome! I've been corresponding with Paul on a newer top clamp with a very sexy set-up inspired by yours...I'll either post up here (easier to search for fellow inmates) or create a new one...

    Makes me want to get a WR!
    #21
  2. OKDQ

    OKDQ Been here awhile

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    Here are pix of my handguards installed.

    Anodized top clamp with ram ball installed on bracket.
    [​IMG]

    Handguard with mirror
    [​IMG]

    Handguard and mirror as seen from the front of the bike. Note here that you can see the brakeline rubbing against the handguard bar - will loosen the banjo bolt and move brake line up just a tad and all should be good.
    [​IMG]
    #22
  3. bash3r

    bash3r I ain't no DingWeed

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    OKDQ.. looks nice!!! Hey you got a part # for that RAM ball, I want to do the same thing, and there are two types of "balls", I need to make sure I get the right one :D

    thanks!
    #23
  4. DiscoDino

    DiscoDino Long timer

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    x2!
    #24
  5. OKDQ

    OKDQ Been here awhile

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    No part number, the one in the photo actually came off of another old holder I had - it is not exactly the right size (shaft is too long). I ordered the RAM-TINY (1/4"x20) and should get it this week. I'll let you know if that turns out to be the right size or not.
    #25
  6. ejtv

    ejtv Per ipsum

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    This guy http://vimeo.com/9038421 has a pretty good video of how he installed his HDB clamps. I followed the same steps on mine.

    Here are a few pics of mine:

    Taking the old clamps off: Right side in the WR250R was a real pain. Needed a 19 mm deep socket and followed the above video's tips.
    [​IMG]

    After installing the 3 Circuit Solution by Eastern Beaver, I pre-installed the whole rig and tested the connections to make sure the Hotgrips, powerlets and switches were working before glueing the Hotgrips and to make sure everything, including the handguards fit together. I had to saw off the edge of throttle sleeve (not sure if that is how it is called) to fit the handguard bolt on the throttle side (obvious to many, but I'm new to this and had to wonder....). I did not have to bend the bars to make them fit.
    [​IMG]

    Here is how it looked before glueing. Seemed pretty good to me:
    [​IMG]

    After installing the Hotgrips for real and making all the electrical connections with posilocks I used zip ties and electric tape to tidy up and weatherproof them into one piece and then pushed it down into the steering column with the rest of the stock electric wires.
    [​IMG]

    Here is where I bought the ram ball, 3/8" 16 thread, then installed with a lock nut and nut.

    I did have difficulty installing the low profile Powerlets. The top clamp as too thick for this socket style, so I could not use the stock rubber washer. I had to make one from a bicycle tire inner tube.

    I was able to use electrical tape it all the way down to the loom that contained all the 3 Circuit Solution cables. To the right of this picture you may note that the brake line can rub against the handguards. I had to loosen the brake line bolt and rotate it towards the steering column in order to be able to adjust the front break lever to what I consider the optimal position.
    [​IMG]

    Overall I am extremely happy with the HDB products. The owner answers questions via email rapidly, is very helpful and is accommodating with returns. I understand he can also custom size the various top clamp holes for your switches.
    #26
  7. Assfault

    Assfault Exposed Member

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    Just want to chime in a report my great experiance with Paul @ HDB.
    He answered all of my dumb questions ans got me what I wanted quick.
    Thanks HDB!
    Assfault
    #27
  8. ejtv

    ejtv Per ipsum

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    Couldn't get the correct angle to my mirrors given the current angle and location of metal hand-guards/handlebars, so I sawed about a square inch off the outer top edge of both plastic hand-guards. Not most elegant solution, but it worked for me:

    [​IMG]


    This allows a greater than 90 degree angle for the mirrors:

    [​IMG]
    #28
  9. joenuclear

    joenuclear Planning.....

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    #29
  10. GeckoRider

    GeckoRider Been here awhile

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    Reading the PDF directions for the guards it mentions having to tap the bar ends. I am decent with tools but I have never tapped metal before. What sort of skill level does a person need to pull off this job with a fair degree of confidence? Thing that pop into my ignorant mind is not starting the tapping at a correct angle and ruining the bars for example.

    TIA.
    #30
  11. DiscoDino

    DiscoDino Long timer

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    Basic level needed...Just make sure everything is centered/aligned...Drive in, WD40, drive out...And you'll be done...very simple
    #31
  12. cross-country

    cross-country .

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    More than likely, measure your bolt spacing and go to the HDB website. You will have to go through the different spacings found on different bike manufacturers stock stuff. I did this for my BRP clamp on my 950 and found what I needed.
    #32
  13. Chadx

    Chadx my toot toot

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    I took the easy way out. Since I needed new bars anyway, I ordered them from Paul the same time I ordered the handguards, top clamp, lower clamps, etc. (he can get you any bars you want) and he tapped them for free! :thumb
    #33
  14. Chadx

    Chadx my toot toot

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    Good solution. I imagine it depends on how you fit/angle the handguards. I can see how fitting the handguards at a higher angle might necessitate this adjustment. I think my handguards will be angled down enough that it won't be necessary, but I haven't finished tightening everything up yet, so time will tell.
    #34
  15. joenuclear

    joenuclear Planning.....

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    I'm not sure if the hand guard brackets will clear the forward mount Scott stabilizer post. I'm having to install stand offs to use the Trail Tech X2 dual sport light.
    #35
  16. bash3r

    bash3r I ain't no DingWeed

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    Just FYI for others looking for the RAM Ball Mount, I picked mine up from gpscity.com Part Number: RAMB236U

    Fits perfect on the top clamp, get a nylon lock nut for the under side and call it good!
    #36
  17. Chadx

    Chadx my toot toot

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    Yep, that's the same one ejtv specified he installed up above with a link to Rocky Mountain.
    It's nice to have multiple verification that the 3/8"-16 is a good one to use.

    By the way, since gpscity won't find that part number without the dashes, search for this: RAM-B-236U.
    Or better yet, here is the link, click RAM-B-236U
    [​IMG]


    Right now, I have the one that screwed directly into my unused mirror mount. I should check to see if that thread will fit threw the top clamp switch holes. If not, I'll either order the one you guys suggested above or the one below that replaces one of the top clamp bolts, like this: RAM-B-367U


    [​IMG]


    [​IMG]
    #37
  18. OKDQ

    OKDQ Been here awhile

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    #38
  19. Chadx

    Chadx my toot toot

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    Good to know. By the way, I tried the ball that I currently have screwed into my vacant mirror mount and that thread (whatever it is) is too large to fit through the vacant top clamp switch hole.
    #39
  20. Chadx

    Chadx my toot toot

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    Mostly finished the handguard install today. Here is a shot before putting on the mirrors and shields.

    [​IMG]





    Shot from the back. As mentioned earlier, I used custom HDB lower clamps with about 2" of rise over my stock clamps. The bar bend is 1/2" lower than stock netting me 1.5" of rise over stock.
    [​IMG]


    Here it is with the shields and mirrors installed. In this photo, I've changed the handguard orientation compared to the first two photos. They are angled lower here to improve the view from the mirrors. I think they will still give me the needed protection from wind and branches. I'll adjust them to their final position once I get a few rides in. Note the clutch is out of final position in this image, as are some of the other controls. I was still tweaking positioning of everything.

    [​IMG]
    #40