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Fitting Hand Guards to Standard Bars Fitting Hand Guards to Standard Bars
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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 4 Feb 2015
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Fitting Hand Guards to Standard Bars
Hello again.

I'm trying to replace stock plastic brush guards with aluminium reinforced 'barkbuster' style BUT the stock bars seem to have fixed threads for the stock bar ends and don't allow space for new inserts. Am I missing something here or do i need to think about new bars too? I don't really want to replace the standard bars as I prefer the idea of bendy steel rather than snappy ally if the worst happens

Any advice / thoughts appreciated!

PS for those following my Acerbis tank shenanigans its fitted and doin its thing - whoop!

Thanks.

Braddan.
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Old 4 Feb 2015
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Yes buy new one, its heavy and filled in the end. Dont worry about snapping.
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Old 4 Feb 2015
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Fitted ally ones to my standard bars. Crashed lots and just bent then back into shape.

You'll need to take the bar ends off and lob them into a bush to fit, remembering that it's an XT and no amount of bar end weight will dampen vibrations.

Note my riding buddy fitted fully plastic ones and didn't break them or need to bend them back into shape when he crashed. Moral there I think.
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Old 5 Feb 2015
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Thanks Guys. Charles - That's what I hope top do but I have removed the barends from the stock bars on my 93xt600e but there seems no space for the inserts that came with the guards. There appears to be a solid piece in the end of the bar that the bar end is attached to with an allan bolt - am I being dim? does this inner section come out too? Any thoughts appreciated!
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Old 5 Feb 2015
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Drill and Tap to fit barkbuster allen screws.THUMPTHUMP
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Old 6 Feb 2015
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Gotcha...
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  #7  
Old 6 Feb 2015
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If I remember correctly. They are internal weights. Jammed in with rubber. You can get them out but it's a right tw*t of a job. I use a slide hammer but I appreciate most people don't have one.

If you can drill and tap as suggested, it's probably the easiest way.
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Old 13 Feb 2015
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Thanks TT
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Old 13 Feb 2015
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Whats easy is buying new/used and you get them cheap if you want steel bars, then you can use original montings.
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Old 16 Feb 2015
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Makes sense! Thank you
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