In the USA, probably 99.9% of moto dirt / dual-sport / ADV handlebars are 7/8" (outer diameter) size at the handgrips. This is SAE (American) sizing. So the 5/8" x 11 tap is also SAE (American).
I bought a nice tap from Fastenal. My issue is that one side was small enough. The other side was larger than my drill....The drill barely caught any material. The tap doesn't catch. Not sure if the previous owner drilled it out larger or what, but I have one side tapped and side with the expansion thingy. I made my inserts a bought stainless bolts though. I used a nylon plug with a hex inside for inserting it. (bought a large bag of them cheap from the internet). I drilled a hole in a piece of plywood and tapped that for the OD of the nylon plug. Then inserted it in to the plywood. Then I drilled and tapped the plug that for the bolt. This was back when kits were crazy expensive and only one of two companies made them. Its held up for years. I did my wife's 125 like that. I have not done her 200 yet.
Hello, I got a 7/8s handlebar without threads. I need to thread them with a m16x1.5 so they'll work with OEM bar ends. How do I go about figuring out what I need?
Added comment. Unfortunately KTM Neken Bars 2020 and later have too small a diameter to tap 5/8-11. inside diameter much smaller than 27/32". Gonna need to be very brave and size it up with the above drill bit. Purchased a bit today 🙏
I came up with this product and put it on the market in the early 2000s , sold under the name Atek Racing. Do you have a measurement on the current KTM bars? Need 17/32 for 75% thread on the 5/8-11 threads. So many places copied the product I stopped making them.
Cycra bend like tinfoil that they are on simple drops. Highway Dirt Bikes best you can get and you only need one set EVER. Plus Paul is local to Colorado and supports our trails. So yeah they cost more but for good reason. I have a set to go on the GasGas to replace the Cycra (second set) that didn't last that long. However my XR650R still is on the first HDB set and has taken harder falls. I should also mention HDB did away with needing the insert their bolt now is big enough that you thread the bar and the bolt just bolts into the bars. The reason they don't come with them is the idea is plug and play so idiots don't mess up their bike. It's just marketing and knowing customers can be morons. Also you didn't mention that if you have Twin Wall bars like my GasGas you need a different insert which they make as the bar has a wider hole.
Meeker Extreme I forgot about the twin walls. I have the same set of cycras on my bikes that I started with. I’ve not had an issue with them. The HDB ones are definitely burly but I just can’t look at them. I know that’s silly but I think they are just not attractive and they weigh a ton. Not a big deal on a 650 but it makes a difference on a little bike up that High.
Great tutorial. Love the personality. Get 'er done. Thanks 👍
Nice video showing how easy they are to install. I used some old 30wt motor oil to cut the threads.
In the USA, probably 99.9% of moto dirt / dual-sport / ADV handlebars are 7/8" (outer diameter) size at the handgrips. This is SAE (American) sizing. So the 5/8" x 11 tap is also SAE (American).
I bought a nice tap from Fastenal. My issue is that one side was small enough. The other side was larger than my drill....The drill barely caught any material. The tap doesn't catch. Not sure if the previous owner drilled it out larger or what, but I have one side tapped and side with the expansion thingy. I made my inserts a bought stainless bolts though. I used a nylon plug with a hex inside for inserting it. (bought a large bag of them cheap from the internet). I drilled a hole in a piece of plywood and tapped that for the OD of the nylon plug. Then inserted it in to the plywood. Then I drilled and tapped the plug that for the bolt. This was back when kits were crazy expensive and only one of two companies made them. Its held up for years. I did my wife's 125 like that. I have not done her 200 yet.
Hello, I got a 7/8s handlebar without threads. I need to thread them with a m16x1.5 so they'll work with OEM bar ends. How do I go about figuring out what I need?
My Yamaha FZ1 had the inserts spot welded In place.
Added comment. Unfortunately KTM Neken Bars 2020 and later have too small a diameter to tap 5/8-11. inside diameter much smaller than 27/32". Gonna need to be very brave and size it up with the above drill bit. Purchased a bit today 🙏
I came up with this product and put it on the market in the early 2000s , sold under the name Atek Racing.
Do you have a measurement on the current KTM bars? Need 17/32 for 75% thread on the 5/8-11 threads.
So many places copied the product I stopped making them.
Thanks just what I needed
Awesome
Great video!, very helpful
Thanks. Glad to help
Thanks for the tip i didn't even know they had those. Mine are always moving on me when i crash.
Brian Wiechman these are the best
I need to do this. I absolutely hate my handguards they always end up flopping down at the end of a ride
It’s the best
Cycra bend like tinfoil that they are on simple drops. Highway Dirt Bikes best you can get and you only need one set EVER. Plus Paul is local to Colorado and supports our trails. So yeah they cost more but for good reason. I have a set to go on the GasGas to replace the Cycra (second set) that didn't last that long. However my XR650R still is on the first HDB set and has taken harder falls. I should also mention HDB did away with needing the insert their bolt now is big enough that you thread the bar and the bolt just bolts into the bars.
The reason they don't come with them is the idea is plug and play so idiots don't mess up their bike. It's just marketing and knowing customers can be morons.
Also you didn't mention that if you have Twin Wall bars like my GasGas you need a different insert which they make as the bar has a wider hole.
Meeker Extreme I forgot about the twin walls. I have the same set of cycras on my bikes that I started with. I’ve not had an issue with them. The HDB ones are definitely burly but I just can’t look at them. I know that’s silly but I think they are just not attractive and they weigh a ton. Not a big deal on a 650 but it makes a difference on a little bike up that High.
It's easier to just watch Morgan install them 😬
Brent Stogdill hahahaha
Support local small business is my motto 🤙🏼