Barkbusters BHG-121 handguard mounting kit for Zero DS, DSR, and DSR/X from 2023 onward

The BHG-121 is the Barkbusters mounting kit designed for Zero DS, DSR and DSR/X electric motorcycles from 2023 onward. It is the structure onto which Barkbusters plastics are mounted: on its own, it protects levers and hands from impacts; with the plastics, it adds protection from wind, cold and branches.

Key features

• Heat-treated aluminum bars, one right and one left.
• Two-point mounting: at the handlebar end, reusing the original Zero expander, and on a clamp made of two shells tightened around the tube.
• Bar-end weights and expanders not included: the original ones are refitted.
• 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 at both the handlebar end and center, is the one the manufacturer specifies for impact protection. On the Zero DS and DSR, electric dual-sport motorcycles for road and off-road use, this means keeping the levers protected from falls, stones and branches.

Materials and construction

Heat-treated aluminum bars (manufacturer code BAR-V-042), CS-01 two-piece clamps with CP6 connectors. The manufacturer does not specify the finish or the kit's weight, so we do not report them.

Compatibility

Do you have a Zero FX or FXE? The kit is the BHG-125.

The manufacturer specifies that fitting tests are carried out on stock motorcycles, with the original handlebar and windshield in their factory positions.

Installation

Remove the original handguards and bar-end weights, retaining the original expander and expansion nut: the bar is secured directly to them. Fit the clamp without tightening it, observing the reference rings, secure the bar at the end and to the connector, horizontal when viewed from the side, and tighten in this order: M8x45 end bolt, M8x25 bar bolt, M6x25 bolt, M6x30 bolt.

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

What's included

• 2 aluminum bars, right and left
• 2 pairs of two-piece shells and 2 connectors
• 2 7 mm spacers
• Hardware: 2 M8x45 countersunk-head bolts, 2 M8x25 button-head bolts, 2 M6x30 bolts, 2 M6x25 bolts and 4 M6 self-locking nuts
• Official INS-BHG-121 instructions

What is NOT included

• Protective plastics. The kit is the structure only: the plastics must be purchased separately from those listed by the manufacturer.
• Expanders and bar-end weights: the motorcycle's original ones are reused.
• Threadlocker and tools.

Plastics to pair with it

• JET-003: compact profile, for off-road and mixed use.
• VPS-003: deflector adjustable to two positions. It is being phased out, and the price list indicates the 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 application-specific kit is designed around the geometry of a particular 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 changing the kit.

Why buy it from Endurrad

At Endurrad, every Barkbusters product page states 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.