Well I have recently fitted new handlebars and Barkbusters.

Are you keeping the standard bars?? (they bend if you fall off alot like I do)

Anyway, apparantly if you insert the bolt back into the bar end insert and tap it inwards a little, it should free up, and you can remove it. I tried this, and even after a 24 hr soaking in WD40, and lots of heat, they didn't budge.


Why don't you get some stronger bars, forget those inserts, and do what I did?

http://www.xt660.com/showthread.php?t=15842

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2008 XTR Mods : DNA Stage 3 Airbox, PC111, Carbon Cans Ovals, Steve Ruth built XTR734cc Big Bore with - High Desert Dyno (HDD)/ Cuervo Racing Gas Flowed / Ported Head fitted with +1mm Valves & uprated Springs, HDD 5050 Camshaft, HDD +3mm Throttle Body, CP 105.5mm 11:1 Piston, Custom Mapping, Piasini ECU, Renthal 613-01, Barkbusters VPS, Pivot Pegz, Touratech Bashplate, Foam Grips, Kev's O2 Sensor Mod, Kev's Extra Coolant Cooler, Wilbers Progressive Fork Springs and Rear Shock