Jump to content
shigeta

How To: Install Barkbuster Storm Handguards


Recommended Posts

While the FJ-09 isn’t designed to go off-road, I (of course) take it there. The 17″ wheels and low ground clearance means that my pace is slow and the trails are easy, but despite my caution, I had a mild low-side on a trip in AZ last year. Given the design of the bike, it was no surprise that the left hand guard and some plastic bits tore straight off. That’s when I decided I needed some beefier protection. Barkbuster was the first name that came to mind.
 
After a few thousand miles with these in temps between 32° and 100°; rain and shine, I can definitely say that they offer superior protection from the elements. I haven’t crash-tested them yet, but the peace of mind from their durability over the stock hand guards in addition to their weather-isolation has made this one of the best mods on my bike so far.
 
 
33954345813_06e95c38cf_b.jpg
 
 
[b style=font-size:large]Enter the Barkbuster Storm Hand Guards.[/b]
 
 
[b style=font-size:large]33954351513_19bc9d0250_b.jpg[/b]
 
 
Barkbuster put together this FJ-09-specific kit which includes everything you need to replace your weak factory plastic hand guards.
 
The steps are pretty simple:
 
[ol type=""][*]Remove factory hand guards and threaded inserts
[*]Install Barkbuster threaded inserts
[*]Loosely attach handlebar clamp
[*]Loosely attach backbone to handlebar clamp and threaded insert
[*]Torque to spec
[*]Install handguard plastics
[*]Repeat on opposite side[/ol]
Here are all of the components of the backbone laid out:
 
33954348033_004cf90264_b.jpg
 
[b style=font-size:x-large]Step 1: Removing Factory Hand Guards and Inserts[/b]
33954341873_3f212ea093_b.jpg
To remove the hand guards, you’ll need to first remove the mirrors and 10mm bolts below the clutch and brake perch holding the hand guard brackets on.
 
Then, unbolt the allen head bolt from the bar end.
 
Finally, remove the factory threaded insert using a 12mm hex socket.
 
Repeat on both sides.
 
 
33954342793_fae2cbb4f9_b.jpg
 
 
33954341873_3f212ea093_b.jpg
 
[b style=font-size:x-large]Step 2: Installing the Barkbuster Threaded Insert[/b]
 
Thread the Barkbuster insert into the bar by hand, then tighten using a 17mm open-end wrench. I torqued this to approximately 25 ft/lb.
 
33954340823_9a0dc16a78_b.jpg
 
33954339923_5fdb7df4f0_b.jpg
 
[b style=font-size:x-large]Step 3: Loosely Attach the Handlebar Clamp[/b]
 
Next, you want to bolt on the clamp that attaches the inside of the backbone to the handlebar.
 
34762681385_80b2c5914f_b.jpg
 
34631112641_56a977e25f_b.jpg
 
[b style=font-size:x-large]Step 4: Loosely Attach the Hand Guard Backbone[/b]
 
Now, you want to attach the back bone of the hand guards to 1) the threaded insert in the bar end and 2) the handlebar clamp you just loosely installed.
 
34762682515_1aeb6da0f3_b.jpg
 
34762681915_e735c2ac33_b.jpg
 
[b style=font-size:x-large]Step 5: Tighten Everything Down[/b]
 
Now that the back bone is attached, you can align all the pieces how you want and tighten everything down.
 
34762683115_956b1081df_b.jpg
 
34631112961_b9f5fca385_b.jpg
 
34631112241_4f656114a2_b.jpg
 
34762680905_369759ea4d_b.jpg
 
Step 6: Attach the Plastics

With the Barkbuster system, you can attach any plastics to this back bone—Storm, VPS, JET, or their Carbon pieces. I chose the Storm as they offered the best protection against the elements as well as the most subtle styling.
 
The plastics come with 6 screws and 2 brackets. Each handguard uses one screw on the front and 2 screws to attach the bracket on the back side.
 
 
33954349613_c4bf8c3bbc_b.jpg
 
Align the plastics with the hand guard and install the largest screw using a Phillips driver.
 
34631111951_c6e60acf98_b.jpg
 
Next line up the bracket on the back side and install its two Phillips screws. This is how the bracket is aligned. If you put it on backwards, it won’t hold the plastics on.
 
34762680425_6b8775c42b_b.jpg
 
34631111561_61b62eb9e8_b.jpg
 
[b style=font-size:x-large]Step 7: Repeat on the Opposite Side
[/b]
Great! You’re done with one side. Rinse and repeat on the other side to complete installation.
 
34631111331_b06d41556b_b.jpg
 
 
 
 

Share this post


Link to post
Share on other sites
While the FJ-09 isn’t designed to go off-road, I (of course) take it there. The 17″ wheels and low ground clearance means that my pace is slow and the trails are easy, but despite my caution, I had a mild low-side on a trip in AZ last year. Given the design of the bike, it was no surprise that the left hand guard and some plastic bits tore straight off. That’s when I decided I needed some beefier protection. Barkbuster was the first name that came to mind. 
After a few thousand miles with these in temps between 32° and 100°; rain and shine, I can definitely say that they offer superior protection from the elements. I haven’t crash-tested them yet, but the peace of mind from their durability over the stock hand guards in addition to their weather-isolation has made this one of the best mods on my bike so far.
 
 
33954345813_06e95c38cf_b.jpg
 
 
[b style=font-size:large]Enter the Barkbuster Storm Hand Guards.[/b]
 
 
[b style=font-size:large]33954351513_19bc9d0250_b.jpg[/b]
 
 
Barkbuster put together this FJ-09-specific kit which includes everything you need to replace your weak factory plastic hand guards.
 
The steps are pretty simple:
 
[ol type=""][*]Remove factory hand guards and threaded inserts
[*]Install Barkbuster threaded inserts
[*]Loosely attach handlebar clamp
[*]Loosely attach backbone to handlebar clamp and threaded insert
[*]Torque to spec
[*]Install handguard plastics
[*]Repeat on opposite side[/ol]
Here are all of the components of the backbone laid out:
 
33954348033_004cf90264_b.jpg
 
[b style=font-size:x-large]Step 1: Removing Factory Hand Guards and Inserts[/b]
33954341873_3f212ea093_b.jpg
To remove the hand guards, you’ll need to first remove the mirrors and 10mm bolts below the clutch and brake perch holding the hand guard brackets on.
 
Then, unbolt the allen head bolt from the bar end.
 
Finally, remove the factory threaded insert using a 12mm hex socket.
 
Repeat on both sides.
 
 
33954342793_fae2cbb4f9_b.jpg
 
 
33954341873_3f212ea093_b.jpg
 
[b style=font-size:x-large]Step 2: Installing the Barkbuster Threaded Insert[/b]
 
Thread the Barkbuster insert into the bar by hand, then tighten using a 17mm open-end wrench. I torqued this to approximately 25 ft/lb.
 
33954340823_9a0dc16a78_b.jpg
 
33954339923_5fdb7df4f0_b.jpg
 
[b style=font-size:x-large]Step 3: Loosely Attach the Handlebar Clamp[/b]
 
Next, you want to bolt on the clamp that attaches the inside of the backbone to the handlebar.
 
34762681385_80b2c5914f_b.jpg
 
34631112641_56a977e25f_b.jpg
 
[b style=font-size:x-large]Step 4: Loosely Attach the Hand Guard Backbone[/b]
 
Now, you want to attach the back bone of the hand guards to 1) the threaded insert in the bar end and 2) the handlebar clamp you just loosely installed.
 
34762682515_1aeb6da0f3_b.jpg
 
34762681915_e735c2ac33_b.jpg
 
[b style=font-size:x-large]Step 5: Tighten Everything Down[/b]
 
Now that the back bone is attached, you can align all the pieces how you want and tighten everything down.
 
34762683115_956b1081df_b.jpg
 
34631112961_b9f5fca385_b.jpg
 
34631112241_4f656114a2_b.jpg
 
34762680905_369759ea4d_b.jpg
 
Step 6: Attach the Plastics

With the Barkbuster system, you can attach any plastics to this back bone—Storm, VPS, JET, or their Carbon pieces. I chose the Storm as they offered the best protection against the elements as well as the most subtle styling.
 
The plastics come with 6 screws and 2 brackets. Each handguard uses one screw on the front and 2 screws to attach the bracket on the back side.
 
 
33954349613_c4bf8c3bbc_b.jpg
 
Align the plastics with the hand guard and install the largest screw using a Phillips driver.
 
34631111951_c6e60acf98_b.jpg
 
Next line up the bracket on the back side and install its two Phillips screws. This is how the bracket is aligned. If you put it on backwards, it won’t hold the plastics on.
 
34762680425_6b8775c42b_b.jpg
 
34631111561_61b62eb9e8_b.jpg
 
[b style=font-size:x-large]Step 7: Repeat on the Opposite Side
[/b]
Great! You’re done with one side. Rinse and repeat on the other side to complete installation.
 
34631111331_b06d41556b_b.jpg
 
 
 

 
Great write up, thanks for taking the time to do that. Tech tips makes life easier for fellow forum members and really, that is why I created this forum in the first place. Great job!
 

Share this post


Link to post
Share on other sites
You make it look so easy even a girl could do it!!!    (rofl) (rofl) (rofl)
 
Thanks for taking the time to document.
 
 

Share this post


Link to post
Share on other sites
When Yamaha factory heated hand grips are added, the right hand bar end is changed in the kit.  Will The Barkbuster kit work with FJ-09s that have factory heated hand grips?  If yes, how?

Share this post


Link to post
Share on other sites
When Yamaha factory heated hand grips are added, the right hand bar end is changed in the kit.  Will The Barkbuster kit work with FJ-09s that have factory heated hand grips?  If yes, how?
Great question! I have the factory heated grips, so the instructions should apply directly to you. 

Share this post


Link to post
Share on other sites
@shigeta did you manage to install the backbone without unpluging the clutch safety switch? I cannot get the clamp the line up with the backbone unless i unplug that switch.
20171114_140912.jpg
 
20171114_135358.jpg
 

Share this post


Link to post
Share on other sites
@shigeta did you manage to install the backbone without unpluging the clutch safety switch? I cannot get the clamp the line up with the backbone unless i unplug that switch. 
 
 

Hmmm... It's been a while now. I had to wiggle some stuff around as I was installing and it was a tight fit, but it definitely cleared. Have you adjusted your bar/lever angle at all? 

Share this post


Link to post
Share on other sites

Glad I looked at this. I almost ordered just regular barkbusters. There is a specific model for the FJ09. Installing mine tonight. 

Thanks for the great post @shigeta

Share this post


Link to post
Share on other sites

So @shigeta they only send one clamp per plastic side? Even though there’s clearly two per side?

**edit. evidently yes. guess its a good idea to look at the instructions.ha**

Edited by brewhaha

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now


×