Tiger Sport Remove Bar End Inserts?

Midgley · Aug 12, 2023

Is it possible to remove the threaded bar end inserts on a Tiger 660 Sport? I want to install some non-OEM handguards of the type with their own expanding bar inserts. I did have the Triumph handguards but the right hand one was broken in a very minor, low-speed off as were both my brake levers. They may work well as brush and wind guards but they ain't protecting nothing.

If it IS possible, are there any gotchas I need to know about such as internal tabs/retainers etc. before I have at it with a slide hammer?

Thanks for any and all advice!

ManInTheJar · Aug 14, 2023

Midgley said: ↑

Is it possible to remove the threaded bar end inserts on a Tiger 660 Sport? I want to install some non-OEM handguards of the type with their own expanding bar inserts. I did have the Triumph handguards but the right hand one was broken in a very minor, low-speed off as were both my brake levers. They may work well as brush and wind guards but they ain't protecting nothing.

If it IS possible, are there any gotchas I need to know about such as internal tabs/retainers etc. before I have at it with a slide hammer?

Thanks for any and all advice!
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Why not replace the expanding bar inserts with long bolts/ allen screws which fit the threaded inserts. I have done this many times for hanguards and bar end mirrors. You might need to make a spacer on the throttle side if it binds on the guard, this can be done simply using stacked washers or I use a piece of round alloy bar cut to length to make a spacer.

speeder · Aug 14, 2023

Couldn't get mine out either, the bolt for the bar end mirror was bigger (8mm) so l simply drilled out the existing thread and re-tapped it out to 8mm.....problem solved.