Removing original handlebar end inserts (for Acerbis handguard mounting)
 

Just got my first bling bling parts for my XT660R: Black Acerbis Rally Pro handguards. These are a must have according to the all-knowing forummembers of this great homepage.

I started removing the original ends and then found the original inserts were pretty tightly stuck inside the handlebars... How do I get them out? :088:

Solutions:
1: Mount the new Acerbis handguards in the original insert. Downside being lack of stabilizing as the new inserts have a profile fitting in the handguards)
2: Remove the original insert somehow - tried pulling quite a bit but it would not move a millimeter.
3: New handlebar ;o)
4: Have a mechanic help me (:toothy5:)

I searched the forum and it seems keeping the original end-weights will keep the vibration og the handlebar ends down - I will try to do so!

Thanks a bunch!

I,ve got the Yamaha\Acerbis guards fitted on my XTX and the bar end waights are still fitted.
Cheers BEAR

Thanks Bear - I am planning to fit the weights as well. However I would like to put the expanderbolts from the Acerbis kit in the handlebars - the original ones there are not that easy to get out...

The originals on mine were fitted with a bit of glue.That meant that you couldn't pull them out until you had broken the glue.

Back the fitting nut out until it sits just proud of the bar end.

Then smack it with a wooden/rubber mallet. Wood or rubber wont damage the bolt head. It should pull out easy enough then.

Hi Bishop
That sounds like something even I can manage to try. Will give it a go!

Go to your local friendly KTM dealer... they have standard fittings for our bikes on their ones. Also they often have bits lying about.

No luck in whacking it with wooden stuff - there is a rubber thingy cushoning the blow I think... Maybe I should just buy a new handle-bar...

Think I had the same problem.
Bought a pair of bark busters. The fitting was for a hollow bar. So sent it back for a refund (which too ages to come through)
Bought a pair or yamaha's own, Fitted like a pair of gloves.
Unfortunately, I felt I was getting more vibes so sold them!

Hi! Have the same problem! Did you find any solution??

the same problem as who? mine?

Hehe...... good question! But it is the rubber in the bars i cant get out





So.......if anyone have a solution?

Hi,
I had the same problem with the original inserts, but finally solved it! Drill the rubber :110:

https://plus.google.com/u/0/photos/1...38371374435073

Hope it helps!

I am in the same situation. (It seems some people get the inserts out without any problems. Perhaps there is more than one version of these inserts?)
Even heating up the bar end with a weed burner to well over boiling point (naked steel, all other parts removed) would still not make the %�"&#� thing budge one mm. :angry:

Next step is to drill the rubber but I am sure it will take a long time, the outer pipe section will be hard to pull out and it is non-reversible.

I really hope the Vibranators are worth this mess...

they are... more than halfed the vibes on the XTR...

I replaced the bars with "CR high" fat bars..
made the vibanators & some very heavy end weights...
Also packed the lower section of the bars with sand up to
the 2nd bend..used corks to hold the sand in place...

http://imageshack.us/a/img708/781/ynqi.jpg

Mounted Acerbis Rally Pro handguards today. Removed the stock inserts using the following 3 minute per side procedure:

1) Remove the bar end weights ( easy )
2) Use a metal drill bit to drill many straight holes though the rubber (avoid the center and the bar itself), circle wise.
3) After most of the rubber is gone insert some M6 bolt in the stock insert
4) Hold tight into the "pull bolt" with Tongue-and-groove pliers and pull hard ( do make sure to keep your bike stable )
5) After the stock inserts are out of the way, cleanup the inside using round file

DutchXT's description is spot on.
I did that and put my Vibranators in with very limited success. A slight improvement across the rpm range where vibrations were not problematic before. However, there is virtually NO improvement at highway speeds, even though I specifically described where I wanted the Vibranators to be "tuned" when I ordered them.
I have e-mailed Don twice for support or suggestions but he has not bothered to reply to my e-mails.

I can not recommend the Vibranators to anyone running an XT660.

By the way, my kit has a different design than Petenz's.

By the way, how did you manage to separete the screws from the inserts?
In my case, un-screwing the screws seems to make them "wedge" very hard ones you reach a certain point. Fixing the weight in a vice allows for more torque to be applied, but one of the screws will definitely not want to separate from the insert.
The other one might be coming out with more force.

They (obviously) arrived "new in box" (I hope) with the screws in place.