Installing custom handguards such as Barkbusters on a KTM 950 or 990 Adventure model can significantly enhance both the functionality and aesthetics of your motorcycle. Designed to protect your hands from weather and road debris, Barkbuster handguards are a popular upgrade among off-road and touring riders. This article provides a detailed, step-by-step guide based on user experiences and practical insights from the installation process on a KTM 950/990 Adventure with tapered handlebars.
The following guide draws from firsthand accounts and technical observations to ensure accuracy and relevance for U.S. riders and DIY enthusiasts. It focuses on the specific challenges and considerations when installing these handguards on a KTM model equipped with tapered bars, which may differ from standard straight-bar configurations.
Understanding the Components and Purpose
Barkbuster handguards are designed to serve dual functions: weather protection and impact resistance. Unlike the stock plastic wind deflectors that come with many KTM models, Barkbuster units are constructed from a thick aluminum bar that clamps to the handlebar in two places and then connects to the plastic wind deflector. This design not only shields the rider's hands from wind and rain but also provides a robust barrier against branches, rocks, and other debris during off-road riding.
For riders of KTM 950 or 990 Adventure models, the installation involves adapting the handguards to the unique geometry of the tapered handlebars. These bars have a narrower end, which can affect how the clamps and mounting points fit. The installation process, as detailed in multiple user accounts, requires careful attention to alignment and fitment.
Preparing for Installation
Before beginning the installation, it is essential to gather the necessary tools and materials. Based on the provided documentation, the following items are typically required:
- Allen wrench set (for removing and tightening bolts)
- A center stand (for aligning the handguards properly)
- Optional: Thread locker (such as Loctite) to prevent bolts from loosening during use
Additionally, riders should ensure that the correct parts are on hand. The Barkbuster Storm Handguards come with an aluminum bar, a plastic wind deflector, clamps marked for left and right sides, and mounting hardware. It is important to note that some users found it necessary to use the supplied expansion bolts and adapt the mounting points to fit the tapered bar ends.
Step-by-Step Installation Guide
1. Removing the Stock Handguards
The first step in the installation process involves removing the factory-installed handguards. These are typically held in place by a clamp at the end of the handlebar and another at the base. Using an Allen wrench, loosen and remove the bolts securing the clamps. Once the clamps are removed, the handguards can be slid off the handlebars.
It is also important to inspect the inside of the bar ends for any threaded holes or expansion nuts. On some models, such as those with Renthal tapered bars, the left side may have a threaded end. If an expansion nut is present, it should be removed to allow for the proper fit of the new handguards.
2. Preparing the Handlebars
With the stock handguards removed, the next step is to prepare the handlebars for the new Barkbuster units. This involves determining the correct orientation for the clamps and the aluminum bar. The clamps are marked with "L" and "R," indicating the left and right sides, but some users have noted that these markings are not always definitive and may need to be adjusted based on fit.
One user reported that there are four potential configurations for the clamps and mounting points, depending on how the aluminum bar and bar ends align. It is recommended to experiment with different setups to find the one that provides the best fit and function.
3. Assembling the Handguards
Once the handlebars are prepared, the next step is to assemble the Barkbuster handguards. This involves attaching the aluminum bar to the clamps and connecting the plastic wind deflector. Users have noted that the clamps should be loosely fastened initially to allow for adjustments.
An important consideration during this phase is the alignment of the levers and controls. Some riders found that the aluminum bar could interfere with the brake or throttle levers, particularly on the right side. If this occurs, it may be necessary to adjust the position of the controls slightly to avoid contact.
4. Mounting the Handguards
After the handguards have been assembled, they must be mounted onto the handlebars. This process involves slipping the bar end (with the aluminum bar attached) into the end of the handlebar and securing it with the front mounting point. The clamps should be tightened gradually to ensure even pressure and proper alignment.
One user emphasized the importance of checking the alignment from the front of the bike. Once both sides are finger-tight, the bike should be placed on a center stand, and the rider should step in front to visually confirm that both sides are aligned evenly. Adjustments can be made at this stage before fully tightening the bolts.
5. Final Adjustments and Testing
With the handguards mounted and aligned, the final step is to perform a thorough check of the installation. This includes verifying that all bolts are securely tightened and that the handguards do not interfere with the operation of the levers or controls.
Some users have mentioned using a small amount of thread locker on the bolts to prevent them from loosening during use. While this is not strictly necessary, it can provide an added layer of security, especially for riders who frequently ride off-road or in rough conditions.
Once the installation is complete, it is recommended to take the bike for a short test ride to ensure that the handguards are functioning as intended. During this ride, pay attention to any unusual vibrations or noises that could indicate a problem with the installation.
Performance and User Feedback
Based on the experiences shared in the provided documentation, the Barkbuster handguards have received positive feedback for both their functionality and durability. Users have noted that the aluminum bar provides excellent protection against impacts and that the plastic wind deflector significantly improves weather protection compared to the stock units.
One rider tested the handguards in rainy conditions and reported that they were able to keep their hands dry at highway speeds, even when wearing warm-weather gloves. While the protection may be less effective in city driving, where frequent stops can expose the rider to more direct rain, the overall performance is considered to be superior to the factory-installed handguards.
In terms of wind protection, users have noted that the stock handguards allowed air to come from underneath, which could be uncomfortable. The Barkbuster units eliminate this issue, providing a more consistent and effective shield against wind.
Potential Challenges and Considerations
While the installation process is generally straightforward, there are a few challenges that riders should be aware of. One of the most common issues is ensuring that the clamps and mounting points fit properly on tapered bars. Some users found it necessary to use the supplied expansion bolts or make minor adjustments to the mounting hardware to achieve a secure fit.
Another consideration is the compatibility with other accessories, such as throttle locks or handlebar-mounted controls. Some riders reported that the Kaoko throttle lock did not fit with the supplied bolts, requiring a modification or alternative mounting solution.
Additionally, it is important to note that the installation instructions for Barkbuster handguards are not always included with the product. As a result, riders may need to rely on online resources or user forums for guidance, as was the case with several of the documented installations.
Conclusion
Installing Barkbuster handguards on a KTM 950 or 990 Adventure with tapered handlebars is a manageable DIY project that can significantly enhance the performance and durability of your motorcycle. By following the step-by-step process outlined in this guide, riders can ensure a proper fit and optimal functionality. The added protection against weather, debris, and impact makes these handguards a valuable upgrade for both on-road and off-road use.
Ultimately, the success of the installation depends on careful preparation, attention to detail, and a willingness to experiment with different configurations to achieve the best results. With the right tools and a clear understanding of the process, most riders should be able to complete the installation without professional assistance.