How to Install Dirt Bike Handguards? | Fit & Secure in an Afternoon

Installing dirt bike handguards takes about an hour and requires loosening the controls, trimming the grips, and mounting the bar-end hardware.

Whether you ride trails or motocross, handguards protect your levers and shield your hands from branches. The job isn’t hard, but doing it wrong can bind your throttle—a dangerous mistake.

What You Need Before You Start

Gather these tools and parts first. Most handguard kits—whether Acerbis, Moose Racing, or HDB Offroad—include guards, mounting clamps, and hardware, but you supply the tools.

• Allen wrench set (metric, typically 4mm–8mm)
• Phillips screwdriver
• Utility knife or razor blade for trimming grips
• Drill and tap set (only for systems requiring threaded bar ends)
• Blue Loctite (threadlocker)
• Torque wrench (if you have specs for your bars)

Check your handlebar diameter first: common sizes are 7/8 inch (22mm) and 1 1/8 inch (28mm) fat bars. The wrong clamp size won’t fit securely and can slip in a crash, so confirm before buying hardware.

Step-by-Step Installation: Loosen, Trim, Align, Tighten

This process works for most kits, but verify your model’s specific steps. Moose Racing’s installation sheet and Chaparral Motorsports’ tech tip follow the same core sequence.

1. Loosen the Controls on the Bars

Loosen the brake perch on the right and clutch perch on the left, sliding the perch clamps up the bar for space. On the throttle side, loosen the throttle housing screws and slide the throttle tube assembly inward— Leave switchgear (starter, kill switch) loose enough to rotate but don’t remove it completely.

2. Trim the Grip Ends

Most systems require an open bar end for outer mounting hardware. Slice the last half-inch off each grip with a utility knife. On the throttle side, cut the throttle sleeve too— If your kit uses a bar-end expander, this step makes inserting the hardware possible.

3. Install Bar-End Hardware or Threaded Inserts

This varies by kit type. Wraparound guards typically need a threaded insert or expander in the bar end. If your kit specifies threaded inserts, drill and tap per instructions. Moose Racing’s aluminum guards use taper lock expanders that grip inside the bar without threading. Open-ended designs (like many Acerbis models) may skip bar-end prep entirely—check instructions before drilling.

4. Assemble and Mount Loosely

If modular, assemble guards on the bench first. HDB Offroad’s system uses a top clamp, swivel bosses, and separate guards bolted together. Position guards on the bike but only snug hardware—leave everything loose enough to rotate and slide.

5. Align for Clearance, Then Tighten in Stages

Adjust each guard to clear levers, cables, wiring, fuel tank, and controls. Moose Racing emphasizes verifying clearance to all these components. Once aligned, tighten in stages: snug the bar-end mount, then the clamp, then recheck clearances. Stop at firm—over-tightening damages bars or brackets.

Finishing Up: Test Everything Before You Ride

Before the first ride, twist the throttle fully and release—it must snap back instantly. Squeeze the front brake lever and verify full travel with no binding. Slaven’s Racing quick tip stresses confirming the throttle closes freely after installation. Then recheck every bolt; vibration loosens hardware, so

If choosing guards, see our tested roundup of the best dirt bike handguards—it covers wraparound versus open-ended designs and which fit common bar sizes.

Does the Install Process Differ Between Handlebar Sizes?

Only at the clamp. A 7/8-inch bar and a 1 1/8-inch fat bar use different clamp hardware or shims—the rest is the same. Follow brand-specific clamp steps precisely.