Hey guys so I know the 07 and older 610's came w/ 7/8" bars and after doing some research it seems the stock Husky bars have too small an ID for most expansion type/threaded bar end inserts to work. Based on my rough measuring I have the following: OD Bar = 7/8" ~ 0.875" ID Bar = 11mm ~ 0.43" EMGO Inserts = 17mm ~ 0.67" After doing some reading it looks like someone mentioned a 33/64 drill bit ~ 0.52" to install Cycra handguards and many people mentioned you'll need to drill them out for virtually any handguards to work. That being said, has anyone put specifically EMGO guards or any guards for that matter and drilled it out successfully? My inserts seem to be about .15" bigger than the Cycra ones and I'm worried removing about 50% of the bar wall thickness will mess with the strength, albeit the insert will be in there filling the space and it's not the whole bar but what do you guys think? Lastly, is it something I can do with the bars on the bike and a regular drill? Another option would be to find a threaded insert that isn't as big as my expansion inserts, drill and tap it for that but it seems like drilling + tapping requires a lot more precision than just expanding the ID. Thanks!
I had to drill out the bar ends on my 11 sm630 to install cycra handguards. I used a 9/16 bit because I couldn't find a 33/64 in town anywhere. Drilled in just far enough for the insert. I had to "start" the spread of the inserts before sliding it into the drilled holes so they would grab when I tightened the bolt using a hex wrench. Funny thing is a friend with the exact same bike and exact same cycra guards had no issues at all. The opening was large enough from factory that the inserts fit right in.
So I ended up using a 1/2-13 tap and a E-Z Lok threaded insert. Didn't have to drill anything, just ran the tap through it, the stock ID of the handlebars is close enough to what drill size you need for a 1/2-13 tap. The threaded insert has 1/2-13 OD threads and M8 inner thread that matches the M8 bolts that come with the Emgo handguards, installed photos to come!
Thanks Choudawg for the info on the EzLok! Worked great and now I was able to install my Acerbis Dual Road Handguards.
