Barkbusters BHG-090 handguard mounting kit for Harley-Davidson Pan America 1250 from 2021

The BHG-090 is the Barkbusters mounting kit designed for the Harley-Davidson Pan America 1250 from 2021. It is the structure onto which Barkbusters plastics are mounted: on its own, it protects levers and hands from impacts; with the plastics fitted, it adds protection from wind, cold, and rain.

Key features

• Heat-treated aluminum bars, right and left.
• Two-point mounting: at a threaded insert in the handlebar end and on a split-shell clamp on the tapered section.
• BEC2 bar-end weights included.
• Compatible with JET-003, VPS-003, STM-003, and BCF-003 plastics, sold separately.

Protection and use

Barkbusters clearly distinguishes between the two mounting configurations, and the two-point configuration, anchored both at the bar end and at the center of the handlebar, is the one the manufacturer specifies for impact protection. On the Pan America, an adventure bike for touring and off-road riding, this means keeping the levers protected in falls and your hands protected during transfers.

Materials and construction

Heat-treated aluminum bars (manufacturer code BAR-V-055), CS-04 split-shell clamps with CP5 and CP4 connectors, and BESF5 threaded inserts. The manufacturer does not specify the finish or weight of the kit, so we do not list them.

Compatibility

Watch out for the windscreen. With the handlebars turned fully, the handguard may touch the windscreen or its adjustment lever: the manufacturer recommends keeping the windscreen in its highest or lowest position.

Barkbusters states compatibility for motorcycles in original factory configuration. On aftermarket handlebars, the mounting must be checked before purchase.

Installation

Remove the original handguards and bar-end weights, if fitted. Install the clamp without tightening it, with the rings of the two halves aligned and facing toward the center of the motorcycle; different connectors are used on the left and right. Attach the bar at the end using the threaded insert and to the connector, preferably horizontally when viewed from the side, then tighten in this order: M8x35 end bolt, M8x25 bar bolt, M6x25 bolt securing the connector, and M6x30 bolt closing the clamp.

Specified torque values: 10 Nm for the M6 bolts, 28 Nm for the M8 bolts, and 21 Nm for the threaded insert, using medium-strength threadlocker and checking everything after the first 50 km. Leave approximately 3 mm of clearance between the throttle grip and the handguard. Barkbusters recommends professional installation.

What is included

• 2 aluminum bars, right and left
• 4 split shells and 2 connectors, one per side
• 2 threaded inserts and 2 BEC2 bar-end weights
• Hardware: 2 M8x35 countersunk bolts, 2 M8x25 button-head bolts, 2 M6x25 bolts, 2 M6x30 bolts, and 4 M6 self-locking nuts
• Official INS-BHG-090 instructions

What is NOT included

• Protective plastics. The kit is the structure only: the plastics must be purchased separately from those specified by the manufacturer.
• Threadlocker and tools.

Plastics to pair with it

• JET-003: compact profile, for mixed use.
• VPS-003: two-position adjustable deflector, for touring. It is being phased out, and the catalog lists VPS-203 as its replacement.
• STM-003, STORM series: more extensive coverage, for the colder months.
• BCF-003, CARBON series: made of carbon fiber.

Why choose Barkbusters

Barkbusters is an Australian brand owned by Rideworx Pty Ltd, specializing in motorcycle handguards. Each vehicle-specific kit is designed around the geometry of a precise handlebar, with a published parts list and an installation PDF specifying the hardware, sequence, and torque values. The structure and plastics remain separate: you can change the plastics series or color without replacing the kit.

Why buy it from Endurrad

On Endurrad, every Barkbusters product page specifies the exact code, the years covered, and what is actually in the box, with the official instructions available for download before purchase. You can find the full range in the Barkbusters collection.