• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Handguard Install Help

C

choudawg

Husqvarna
A Class
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!
 
choudawg said:
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!
Click to expand...



Thanks Choudawg for the info on the EzLok! Worked great and now I was able to install my Acerbis Dual Road Handguards.
 
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