I just got some Acerbis hand guards for my 2010 XT660r. The Acerbis plug has an M8 threaded bolt; the Yamaha bar end has an M6 threaded bolt.

To fit the Acerbis hand guards AND use the bar ends I need to remove the standard plug and drill out the bar end to 8mm. I have removed bar ends from other bikes but these yamaha ones have me stumped. I can't budge them, trying to knock em into the bar didn't work either.

Any Tips? They feel rubbery so lots of loob might help.


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I have just tried removing mine as well.
See what you mean.
I couldnt budge mine either!
Tried vice grips and big hammer - nothing!
I am just going to leave them in as I have a new set of renthals to put on. So will use a raw plug or sleeve anchor to put the old bar ends and gaurds back on.
Sorry I couldnt help.
There might be an old thread on the subject.

I have since browsed through here and across the web. The best I can find is that the plugs are VERY difficult to remove as they are rubber and glued in. I have decided to leave them in and ordered a couple of nice long M6 countersunk bolts instead.


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I'm fairly sure I read a thread a long while ago on this and the outcome was they just needed a bl00dy good bashing. Ive tried searching it but cant find it.

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