How To: Handguard Install ( using threaded inserts )
  • User avatar
    paul turner
    Posts: 7578
    Joined: Thu Sep 22, 2005 9:03 pm

    How To: Handguard Install ( using threaded inserts )

    by paul turner » Tue Sep 23, 2008 9:07 pm

    Here we tap the FatBar end with a 5/8"NC tap, to accept the threaded inserts. Start very slow and straight, as aluminum does not self align the tap like steel does. Pull out and clean out debris every couple threads. With the bar pointing downward, whack the top of bar with your hand, and the debris will bounce out. Its OK to tap deeper than desired, as the mount screws are always on the long side. Be sure to do a final cleanout/run-in with the tap after desired depth is reached.

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    Tapping completed.

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    Blue the insert and the newly cut threads. Run the insert home and tight.

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    Here I pound out the grip end using deep sockets (2).

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    I use a de-burring bit to grind the end down to flush with the smooth bore of the grip.

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    Ready for install.

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    We do the same for the throttle tube.

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    Fini ! :) Check the outside of the tube for thinning, and make a judgement call on replacement. They get thin on the outside around the 3rd and 4th fingers, followed by cracking from the end inward.

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    Trial fit for depth assurance, then remove for grip install.

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    Apply liberal Grip Glue to grip and bar, install leaving 1/32" of bar end exposed.

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    Install, adjust, and tighten the crap out of the screws. Job complete.

    Now go hit some rocks :twisted: :P :)


    paul
    If you ain't crashin', you ain't ridin' :-)
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  • ThumperX
    Posts: 1256
    Joined: Sun Jan 14, 2007 11:44 am

    by ThumperX » Tue Sep 23, 2008 9:24 pm

    Sweet!! My next set of hand guards will be cycra's...
    05' CRF250X
    07' CR250R
    02' CRF450R
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    JohnnyAirtime
    Posts: 138
    Joined: Tue Oct 17, 2006 12:43 am

    by JohnnyAirtime » Wed Oct 15, 2008 12:30 pm

    Damn... great idea!

    QUE: What happens when ya brake a bolt off in the insert? .. and your on the trail (besides Ez-out)

    I guess your SOL even if you brake a bolt using the supplied insert/gripper thingy... Cycra has a newer insert which is pretty decent (if ya care)

    And I'm only asking, as last ride... I took a spill and broke my (outer) bolt. But was able to grab another insert out of the chase truck and fix it. Not sure what happened to the rest of the parts/pieces... they might have fallen into the bar. No rattles that I know of, as of late. ;)
    Johnny J.
    Help us fight Children's Cancer. Check us out at http://Cancer-RideForLife.com

    '07 CRF450X
    '15 CR500AFX
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    '04 XR400R (Sold)
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  • User avatar
    RottenRob
    Posts: 814
    Joined: Sat Sep 24, 2005 11:31 am

    by RottenRob » Wed Oct 15, 2008 4:14 pm

    Apply liberal Grip Glue to grip and bar, install leaving 1/32" of bar end exposed.
    Closet Democrat? :shock:
    Life's tough, but it is even tougher when you're stupid.
  • User avatar
    paul turner
    Posts: 7578
    Joined: Thu Sep 22, 2005 9:03 pm

    by paul turner » Wed Oct 15, 2008 4:26 pm

    RottenRob wrote:
    Apply conservative Grip Glue to grip and bar, install leaving 1/32" of bar end exposed.
    Closet Democrat? :shock:



    Fixed :lol: :twisted:

    paul
    If you ain't crashin', you ain't ridin' :-)
    Image
  • User avatar
    OLDFATGUY
    Posts: 743
    Joined: Tue Nov 29, 2005 4:29 pm

    by OLDFATGUY » Wed Oct 15, 2008 4:43 pm

    NICE!!!!!!!
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  • User avatar
    bocephus450x
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    Joined: Thu Sep 14, 2006 9:51 am

    by bocephus450x » Wed Oct 15, 2008 5:01 pm

    paul turner wrote:
    RottenRob wrote:
    Apply conservative Grip Glue to grip and bar, install leaving 1/32" of bar end exposed.
    Closet Democrat? :shock:



    Fixed :lol: :twisted:

    paul


    by conservative grip glue I assume you mean grip glue the WORKS and does it's JOB
    There's no right way to eat a Rhesus
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  • User avatar
    ~R.Dawg
    Posts: 43
    Joined: Sun Apr 09, 2006 8:00 pm

    by ~R.Dawg » Thu Dec 04, 2008 6:12 pm

    Hey Everyone!! Where do you get the threaded bar inserts?
    When in doubt, hit the gas!!
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    crfsonly
    Owner
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    by crfsonly » Mon Mar 19, 2012 8:38 pm

    ~R.Dawg wrote:Hey Everyone!! Where do you get the threaded bar inserts?


    you can find them right here:

    http://www.crfsonly.com/catalog/product ... ts_id/2909
    OEM Parts for Honda - Yamaha - Suzuki - Kawasaki: http://yeltrik.com
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