Handlebar size and bar ends

[Razorburns]

Totally confused here.

Bought some new handlebars and bar-ends. 7/8 inch aluminum bars, appropriately sided bar-ends. Good so far. Pretty stoked to go out today and install them.

The only problem is: While the outside diameter of the bars is in fact 7/8 inch, the INSIDE diameter is roughly 1/2. The bar ends totally don't fit inside. I have 1/2 rubber expansion plugs I purchased at the hardware store that will work.... but the bar ends have a shorty flange on the inner edge that is supposed to go in the end of the handlebars.... and it simply will not.

Did I get the wrong sized bars, the wrong sized bar-ends or maybe do aluminum bars have thicker walls than steel? I'm kind of assuming that the bar-ends are intended to fit into STEEL 7/8 bars.

Any insight is much appreciated for this confused newbee.

[Razorburns]

Got them all on and they look super badass.

Still wondering about inside diameter on most 7/8 bars, and why the difference.

[Vegas Street Rider]

Like anything else, different materials, different specs. Chinese imperfections if not American made. All of the above. Glad you got things squared away. Excited to see pictures when your project is done, or even in progress.

[wacio]

Aluminum is much weaker (softer) than steel that is why they have thicker wall. Otherwise you would probably bend them or crush while installing....

[Razorburns]

Thanks for getting back. Yes, I kind of figured that different manufacturing and materials were the reason.

There was a bit of cursing at my desk here when they came and I eyeballed them together before taking them out to install..... "what the f*** is going on here?".

It all worked out though.

Photos today if the sun decides to cooperate.

[Vegas Street Rider]

Good luck with the sun part. Lived up in Olympia a few years and can relate. Hope you are planning on getting some good rain gear, if you don't already have it.

[Razorburns]

Yes. I've got BIG plans on getting some quality rain gear.

Anyway, here is the side by side comparison for the old gold toned bars (who would choose that on a this bike I just don't even know) with no bar-ends, and the new bars and new bar ends.

I feel the black window box bars and the ends really up the game look and feel wise. Wanting to get black hex bolts for the riser clamps and black top bolts for the shock tubes and the steering bolt. Not sure those are available, but I'll be looking around.

[Vegas Street Rider]

The black bars do dress it up and look more appropriate.

[spldart]

I likey!
Now I'm considering this mod :)

[Razorburns]

Black bars off of Amazon:
https://www.amazon.com/gp/product/B00KHUAX2I

Black bar-ends off of Amazon:
https://www.amazon.com/gp/product/B01CFQNCWE/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1

Mud flap off of Motosport (I have one front and rear, both medium size):
http://www.motosport.com/drag-specialties-rubber-mudflap

[Vegas Street Rider]

I am not a big fan of the mudflaps, but in your environment, I totally understand. Just don't like the look.

[Razorburns]

Yes, here in the Pacific Northwest, anything extra you can do to stay dry is a good idea to consider. We're coming into drier summer months, but by fall I plan to definitely have a good rain suit and water proof boots (or covers).

[alantf]

If it's waterproof boots you want, check out impraperm. Totally waterproof. The dryest boots I've ever had.
:tup:b31.jpg (http://www.gz250bike.com/forum/attachment.php?attachmentid=847&stc=1&d=1497259396)

[alantf]

Also...(just forgot)... for waterproof gear, check out the camping stores. Just as good, and usually a lot cheaper than "genuine motorcycle gear". I've had mine for years now. A quick spray with waterproofer (also from camping store) every year, and it's as good as new.