Crash Bars *grrrr*

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Chuckracer, Aug 24, 2013.

  1. Chuckracer

    Chuckracer Jerkus Maximus

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    Anybody who has successfully re-installed these crash bars more than once and NOT stripped or cross-threaded the shit out of at least one of the front bolts is a God to me. Unbelievable. What a crappy set-up.
    #1
  2. JK1

    JK1 Been here awhile

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    Leave them off simples.
    #2
  3. Chuckracer

    Chuckracer Jerkus Maximus

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    I fall down too often. :huh
    #3
  4. Alblue

    Alblue Adventurer

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    CR,
    You back on a KTM....I got a Madstad set-up for ya.
    Studs in the front solve the stripping problem, not the aggravation.

    Al
    #4
  5. Chuckracer

    Chuckracer Jerkus Maximus

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    Hi Al, how'd the Madstaad set-up work for you? Yeah, as of two weeks ago I'm back on a 950 and couldn't be happier! Well, once I drill and helicoil these bolt holes and change over to a stud mount set-up.
    #5
  6. O.C.F.RIDER

    O.C.F.RIDER Loose nut behind h/bars

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    Stripped one side on my 950, but only after having them off/on MANY times.
    God? Not even close.
    Lucky? That's more like it.

    CW
    #6
  7. gearheadE30

    gearheadE30 Long timer

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    This. Or if studs aren't readily available, buy a long bolt and cut the head off if you're in a pinch. Makes it a LOT easier. I also thread the front bolts first, then the lower tank mounts (which I have enlarged the holes on, and use a nut and washer due to tank warping) leaving everything loose, then loosely bolt the crossbar between the guards, then the rear hook things, then tighten it all down. It doesn't take too long. This is on a slightly bent SW Motech setup.
    #7
  8. Chuckracer

    Chuckracer Jerkus Maximus

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    Could be I'm just a hack...:huh
    #8
  9. Alblue

    Alblue Adventurer

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    Hack-something that hangs off the side of a Motorcycle

    Never even opened the boxes! Bolted on an Aeroflow for big roads and remove for the fun roads. Just had corrado113 make me a lined bag to carry it in.
    Nice to see you back in the fold
    Al
    #9
  10. Orangecicle

    Orangecicle On a "Quest"

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    Chuck: http://www.advrider.com/forums/showthread.php?t=626041

    Makes live very easy. I never fully take off my crashbars anymore. I just undo the frame clamp and the lower mount and then rotate the bars forward. There is enough room to then pull the faring and the tanks. Here's a good example:

    [​IMG]

    We rotated the crash bars, pulled the faring and tanks, and then tuned the bike with the crashbars on. Simple. :clap
    #10
  11. Yellow Pig

    Yellow Pig Allergic to asphalt!

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    What front fender is that? Look good.
    #11
  12. Orangecicle

    Orangecicle On a "Quest"

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    #12
  13. EdGear

    EdGear Edventurer

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    There are several posts on putting studs by the oil tank cover.

    I summarized them here
    http://www.advrider.com/forums/showpost.php?p=16147045&postcount=2881

    If you look at the link I took a slightly different approach.

    On the reinstall keep everything loose until you get every bolt/nut thread started.

    Loosen the top two gas tank bolts. This allows the tanks to move up a bit to get the lower tank mount bolts through.
    #13
  14. SauceSquatch

    SauceSquatch Been here awhile

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    I was so fed up with taking off and putting on the crashbars and then I left them off for a week, sure enough I go down in the rain and narf-up my side AND my shoulder.

    I actually got slightly longer bolts, ditched the clips and the reinstall has gotten much better. But still... The part of the oil change I loath.
    #14
  15. Chuckracer

    Chuckracer Jerkus Maximus

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    Good summary - Thanks Ed!
    #15
  16. gozirra

    gozirra Spam?

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    I drilled out all 4 mounts (crashbars mounts, skid plate mount) and heli-coiled all of them, then added in the studs on the crash bar mounts.
    I WILL PREVAIL!

    or strip everything so bad I need a new Alu frame bit.

    Ps. I only did this because one of my skidplate mounts was stripped when I picked the bike up. Not because i needed more to do.
    #16
  17. DSM8

    DSM8 Where fun goes to die....

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    Look into putting a timcert instead of a helicoil, a much better and sturdier design far as the threads go.

    Mike a bushing instead of a spring is one way to think of it.

    I installed the studs first thing when I got the bike so never had that problem but the base metal is very soft so I would look to this as a more permanent solution over the other.

    Just my .02

    http://www.timesert.com/

    And no not a vendor, just someone really good at stripping threads...
    #17
  18. Chuckracer

    Chuckracer Jerkus Maximus

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    :lol3 My Brotha!! :clap
    #18
  19. Jbone11 11

    Jbone11 11 Been here awhile

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    Back Home Wintery Ottawa, Bleh!!
    Not to hijack...but Chuck....are you the same "Chuckracer" as the one on the Ducati.ms forums?
    #19
  20. SierraJeep

    SierraJeep It's toast

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    In response to the OP...

    I know a lot of folks think the stud idea is the solution to the crashbar remount issue, but doing so overlooks the source of this problem (AND the problem with remounting the bottom bolt of the tanks if you remove them).

    The trick to remounting either the tank or a crashbar is to make sure that all of the bolts going into the top plate (below the front header pipe and above the battery/skidplate) are loose. EVEN IF YOU DID NOT REMOVE ANYTHING FROM THE OTHER SIDE. You don't need to remove any of the other bolts, just loosen them so that the top plate can float around a little to help you line up the last (forth) bolt of the four (usually the one for the crash bar or the tank if you're dealing with that). The top plate moves a bit once even one of the bolts are removed; and if it moves only slightly, it will make it easy to cross-thread the last bolt.

    If you put the studs in for the crashbars, then it may make it more difficult to float that top plate around later when trying to remount the tanks.
    #20