tusk hand guards will not fit? HELP!

srreynolds2003 · 01-23-2008, 08:49 PM

:evil: Not a Happy Camper!
Ok I tried installing my new Tusk Hand guards.

I began installing them and when I cut the end of my grips off I found the ends of my handle bars have some type of Steel plug/Stopper about 1/4" in on both sides.

Do you have any idea what these Stoppers are and How do I get rid of them?

The Sleeve that comes with the Tusk Guards will not fit in the Handle bar ends. See photo's of Steel Plug/Stopper.

Jim · 01-23-2008, 08:53 PM

There like bar end weights or something, someone said it is to help stop vibration...

Drilling them out is your best option, my emgo ones look pretty similar, if they are the same you may need to get something to make it line up (make the bar slightly longer), I used 1 brass bushing per side...

[img]/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=5191& g2_serialNumber=2[/img]

liverchip · 01-24-2008, 12:33 AM

Aftermarket bars.

Jim · 01-24-2008, 12:51 AM

That's a lot more work though isn't it... ?

TeamCheap · 01-24-2008, 03:29 AM

Nice set of handguards you got there.

I bought my handguards right along with a new set of bars when I did mine since I knew about the stock bars having stuff like that in them.

Much easier to just change it all out at once IMO plus I got some really cool looking aluminum blue anodized bars but the downside was the added cost of the bars.

katoranger · 01-24-2008, 08:30 AM

I used an angle grinder and cut enough of the bar end to cut the welds of those plugs and then filed it smooth. It would be easier to get new bars though.

Allen

TeamCheap · 01-24-2008, 08:52 AM

I also just used a 4lb mini sledge hammer to make the holes in my grips by tapping on the end of the grip and pinching it agaiant the handlebar thereby cutting it and they came out with a perfect small round hole.

srreynolds2003 · 01-24-2008, 08:59 AM

Ok, Well I think I am going to try and knock them out first. Do you think and mini sledge with a screw driver or Socket Extension will work??

If I have no luck, then I will probably get new bars...."The Wife will love me for that!"

Anyone recommend a set of Handle Bars?
Does it really make a difference in Steel or Aluminum with Vibration???

I found this Ebay store with Aluminum and Steel bars. What do ya'll think about these?
http://search.stores.ebay.com/RideNo...151524QQsofpZ0

ejcycles · 01-24-2008, 09:33 AM

Try drilling them, then install a slide hammer that guys use for bodywork and slap them out that way... Just an idea!

liverchip · 01-24-2008, 11:27 AM

Quote:

Originally Posted by Jim

That's a lot more work though isn't it... ?

I did mine. Fairly simple upgrade in my opinion. Yes the controls need to be moved, but I had no issues. The grips must be replaced or moved, but they're cheap and easy as well. I also installed risers and had no issues with cable length either.

Jim · 01-24-2008, 01:44 PM

Yeah, I didn't think it would be a lot of work, just a lot more work... Plus you have to buy new bars...

It is really easy to drill them out, start with a small drill bit and drill a hole straight in in the middle of it, then use a bigger drill to finish it. Don't try hammering them out, you could end up bending the bars where it attaches so they are oval and not round..

Drilling it you could do very quickly, and it doesn't cost anything.

srreynolds2003 · 01-24-2008, 02:22 PM

Thanks Jim. I will definetly try that first.....

srreynolds2003 · 01-24-2008, 09:22 PM

ok I took care of the Weight. I drill a small hole in the weld bead that was holding the weight in place and with one good hit of a hammer and screw driver on the weight it broke loose, then the weight went about 2 inches up into the handle bar....so I left it in the Handle Bars... now I have the guards on there.....I took it around the neighbor hood got up to about 50 and it all feels the same.

Jim · 01-25-2008, 12:20 AM

Those look good

I hammered one of mine out, and it went all the way into the bottom, I thought it would drive me crazy so I had to get it out, it was a lot of work... The other one I tried hammering out was welded better and I deformed the bars so I drilled it and rounded the bar back as good as I could..

srreynolds2003 · 01-25-2008, 08:51 AM

I tried Drilling it out first, but I had no luck. So then I decided to drill on the weld. That was a lot easier.

My only problem now is the way the guard wraps around the brake buster box....so I need to figure out a fix for that.

01-23-2008, 08:49 PM	#1
srreynolds2003 Join Date: Aug 2007 Location: Tomball, TX Posts: 382	tusk hand guards will not fit? HELP! :evil: Not a Happy Camper! Ok I tried installing my new Tusk Hand guards. I began installing them and when I cut the end of my grips off I found the ends of my handle bars have some type of Steel plug/Stopper about 1/4" in on both sides. Do you have any idea what these Stoppers are and How do I get rid of them? The Sleeve that comes with the Tusk Guards will not fit in the Handle bar ends. See photo's of Steel Plug/Stopper. __________________ -2005 Sierra SR200-
	0

01-23-2008, 08:53 PM	#2
Jim Join Date: Mar 2007 Location: Abbotsford, BC, Canada Posts: 4,880	There like bar end weights or something, someone said it is to help stop vibration... Drilling them out is your best option, my emgo ones look pretty similar, if they are the same you may need to get something to make it line up (make the bar slightly longer), I used 1 brass bushing per side... [img]/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=5191& g2_serialNumber=2[/img] __________________ "Be excellent to each other" "We are all human. Let's start to prove it!"
	0

01-24-2008, 12:33 AM	#3
liverchip Join Date: Nov 2006 Location: Mystery Spot Posts: 1,223	Aftermarket bars. __________________ 2009 XR650L Big Red Pig Tusk bar risers 2007 X-Moto(Jetmoto) GY250 --mods--- 15/40 sprockets UNI Pod Filter 2007 Shineray TMS 200XYi--Betsy Betsy Mods:______________________ Acerbis DHH headlight FMF Powercore pipe Uni Pod Filter
	0

01-24-2008, 12:51 AM	#4
Jim Join Date: Mar 2007 Location: Abbotsford, BC, Canada Posts: 4,880	That's a lot more work though isn't it... ? __________________ "Be excellent to each other" "We are all human. Let's start to prove it!"
	0

01-24-2008, 08:30 AM	#6
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	I used an angle grinder and cut enough of the bar end to cut the welds of those plugs and then filed it smooth. It would be easier to get new bars though. Allen __________________ You meet the nicest people on a Honda Clone.
	0

01-24-2008, 03:29 AM	#5
TeamCheap Join Date: Jun 2006 Location: directly under the earths sun............NOW Posts: 2,302	Nice set of handguards you got there. I bought my handguards right along with a new set of bars when I did mine since I knew about the stock bars having stuff like that in them. Much easier to just change it all out at once IMO plus I got some really cool looking aluminum blue anodized bars but the downside was the added cost of the bars.
	0

01-24-2008, 08:52 AM	#7
TeamCheap Join Date: Jun 2006 Location: directly under the earths sun............NOW Posts: 2,302	I also just used a 4lb mini sledge hammer to make the holes in my grips by tapping on the end of the grip and pinching it agaiant the handlebar thereby cutting it and they came out with a perfect small round hole.
	0

01-24-2008, 08:59 AM	#8
srreynolds2003 Join Date: Aug 2007 Location: Tomball, TX Posts: 382	Ok, Well I think I am going to try and knock them out first. Do you think and mini sledge with a screw driver or Socket Extension will work?? If I have no luck, then I will probably get new bars...."The Wife will love me for that!" Anyone recommend a set of Handle Bars? Does it really make a difference in Steel or Aluminum with Vibration??? I found this Ebay store with Aluminum and Steel bars. What do ya'll think about these? http://search.stores.ebay.com/RideNo...151524QQsofpZ0 __________________ -2005 Sierra SR200-
	0

01-24-2008, 09:33 AM	#9
ejcycles Join Date: Oct 2006 Location: 11481 State Route 44 Mantua, Ohio 44255 Posts: 1,112	Try drilling them, then install a slide hammer that guys use for bodywork and slap them out that way... Just an idea! __________________ Thanks, Bruce @ Endless Journey Cycles "Phone Calls Only" ~330-274-0098~ Hours: Tue.-Fri. 10:00-6:00 Sat. 10:00-4:00 EST. Dealer for: Lifan, Crossrunner ATVs. http://www.endlessjourneycycles.net
	0

01-24-2008, 01:44 PM	#11
Jim Join Date: Mar 2007 Location: Abbotsford, BC, Canada Posts: 4,880	Yeah, I didn't think it would be a lot of work, just a lot more work... Plus you have to buy new bars... It is really easy to drill them out, start with a small drill bit and drill a hole straight in in the middle of it, then use a bigger drill to finish it. Don't try hammering them out, you could end up bending the bars where it attaches so they are oval and not round.. Drilling it you could do very quickly, and it doesn't cost anything. __________________ "Be excellent to each other" "We are all human. Let's start to prove it!"
	0

01-24-2008, 02:22 PM	#12
srreynolds2003 Join Date: Aug 2007 Location: Tomball, TX Posts: 382	Thanks Jim. I will definetly try that first..... __________________ -2005 Sierra SR200-
	0

01-24-2008, 09:22 PM	#13
srreynolds2003 Join Date: Aug 2007 Location: Tomball, TX Posts: 382	ok I took care of the Weight. I drill a small hole in the weld bead that was holding the weight in place and with one good hit of a hammer and screw driver on the weight it broke loose, then the weight went about 2 inches up into the handle bar....so I left it in the Handle Bars... now I have the guards on there.....I took it around the neighbor hood got up to about 50 and it all feels the same. __________________ -2005 Sierra SR200-
	0

01-25-2008, 12:20 AM	#14
Jim Join Date: Mar 2007 Location: Abbotsford, BC, Canada Posts: 4,880	Those look good I hammered one of mine out, and it went all the way into the bottom, I thought it would drive me crazy so I had to get it out, it was a lot of work... The other one I tried hammering out was welded better and I deformed the bars so I drilled it and rounded the bar back as good as I could.. __________________ "Be excellent to each other" "We are all human. Let's start to prove it!"
	0

01-25-2008, 08:51 AM	#15
srreynolds2003 Join Date: Aug 2007 Location: Tomball, TX Posts: 382	I tried Drilling it out first, but I had no luck. So then I decided to drill on the weld. That was a lot easier. My only problem now is the way the guard wraps around the brake buster box....so I need to figure out a fix for that. __________________ -2005 Sierra SR200-
	0