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As per the title... I'd be surprised if this isn't a common problem, does anyone have any solutions?
My forks are 2021 Pikes, the mudguard is an RRP ProGuard standard cable tie. Looking at a video of Lyriks being bottomed out I believe they'd have the same issue, and so would any other mudguard that fits under the brace. Albeit those made from bendy plastic will deform quietly.
It hits at 10mm before full travel, so rarely happens but the bang is annoying and a little disconcerting. I have 18mm clearance between the guard and the tyre at that point, so there's little danger of it acting as a brake. I was thinking that clearance might be enough to allow a slight improvement by spacing it down a bit with layers of 2228 mastic tape (3 for 5mm). Other (bad) ideas I've had are to deform it with a heat gun, or replace a section with a bit of inner tube riveted in place.
The Crud XL Fender is the only mudguard I'm aware of that wouldn't have this problem, as it has a split design with a soft "tongue" at the front of the rear section. However it has open sides and is pretty ugly.
I put a few strips of self amalgamating tape under the arch then wrapped the arch in more tapeto space it down just enough to avoid this.
The Crud XL Fender is the only mudguard I’m aware of that wouldn’t have this problem, as it has a split design with a soft “tongue” at the front of the rear section. However it has open sides and is pretty ugly.
Works very well though, and easily swaps between bikes.
Even fits on my Stooge's rigid forks with mo issues.
Also works on everything from 27.5/27.5+ up to 29+ 3" tyres.
Had this on my Lyrik with a bent flap of plastic type thing. With careful positioning an RRP proguard max doesn't cause the same problems
Hmm, the Max should fit the same as it's just longer at each end. I don't know how different Lyriks are or what offset yours is, my Pike is 42mm. I'm using the rearmost and 3rd-rearmost tie holes, this is the natural fit position for it on the tyre and fork legs. I guess I need to try pitching it backwards using the next row of holes, and shift it backwards to regain the tyre clearance at the rear.
The Mudhugger EVO has a recessed area that solves this problem:

RRP in natural position hits 10mm before full travel.
RRP at "air scoop" angle or with 2-3 layers of mastic tape on the crown hits 7mm before full travel.
Mudhugger EVO hits 1mm before full travel. Add one layer of mastic tape, sorted.
However absolutely everything else about the RRP is better. No well-informed person with the clearance would run the Mudhugger over the RRP unless you were sponsored or it was half the price. Especially if you saw them side by side. A five year old could tell you the RRP is better.
Surely its the mudguard hitting the fork crown 😀
However it has open sides and is pretty ugly
Afraid to break it to you, but they all looking really ugly...they no doubt serve a purpose (although I'm guessing really thick sticky mud will stop the wheel turning due to the reduce space between tyre and guard to let the mud pass through), but they do look absolutely fugly.
With that in mind, go for the one that doesn't hit anything...
I'm more than happy to be sprayed in all the mank, but I'm pretty sure even after 30 years of this, I'm still fighting against my mum's wishes to try and stay a bit cleaner so I don't break the washing machine (a challenge that I never managed to complete!), so mudguards are just all levels of wrong for me on a MTB. So fully expect this to be ignored as it won't be what the current fashion is or the fact they do a good job.
Open sides are a fail though, I'm far more interested in keeping shite off my fork than my clothes.
I had the same problem, also with a 2021 Pike. As above I replaced the RRP with a Mudhugger EVO and that has solved the problem. Multiple hits and I'd damaged the RRP and snapped a few zip ties.
Curiously, my Lyrik doesn't seem to do the same thing. Not with enough travel left to damage the guard anyway. Lyrik is 2020 27.5, Pike is 2021 29er, so I wonder whether configuration by wheel size is slightly different.
Surely its the mudguard hitting the fork crown 😀
The one that's moving is doing the hitting. Tie breaker in case both are moving or as in this case it depends on the perspective, is that the bigger/most-damaging thing is doing the hitting. If still in doubt and one thing is a foreign object in the operational area of another, it's the latter doing the hitting. If it's still a tie then both are hitting each other.
Curiously, my Lyrik doesn’t seem to do the same thing.
The brace on the Pike looks a bit taller, but these photos probably make it look more of a difference than it actually is. I believe the Lyrik crown is stiffer, but it looks the same shape and size.
https://www.bike-discount.de/en/buy/rockshox-lyrik-ultimate-rc2-29-debonair-tapered-boost-953287
https://www.bike-discount.de/en/buy/rockshox-pike-ultimate-rc2-29-debonair-120-tapered-boost-1049651