[flyingburritobrother]

Wow...very interesting that you had a bolt breakage as well. I'm assuming this is the upper left engine head mount? In your 2000 kms miles, was any of that rougher off-roading? Most of my time is spent off-roading and my breakage happened within 2000 miles. I wonder if the multiple mounting points for the OM bars are causing excessive stress and perhaps the trellis frame needs room to "flex". The H and B (non-solid version) bars I used only mount at the upper engine head and under the beak, this would mean less interference with (assuming) frame flex design. To be clear and a warning to anyone using them/thinking of buying them... Hepco and Becker do not provide torque specs in their installation instructions, when I asked the retailer, they said "tight but not overtight". Then when both bolts failed, they both immediately tried to say I over tightened them. After sales were getting killed because of what happened to me and stringing me along, they finally had the bolt I sent to them analyzed. Failure reason: fatique.

I would suggest you also post your experience on ADVrider because a good number of folks over there are using the Outback bars as well.

Please also share with us how Outback Motortrek responds regarding this. For me, the Motomachines (retailer) and Hepco and Becker response was completely dishonerable.... Beware of using these companies.

Crash bars have been a bit of an interesting journey for me on the Tiger (mine is an 850) I ordered and received the Outback Motortek bars and skid plate for the T850. Delivery took about five or six weeks, but as noted, they are in high demand. That was not a serious issue for me.

I did the install myself, as I've done before on other bikes, and I've also done all the rack installs and centre stand installs. I'm not an especially skilled mechanic, but I do have the necessary tools including a click-type torque wrench. I work carefully and slowly.

I had some fitment issues with the right side upper bar; the right angle upper engine attachment tab was bent too far, and so it did not fit. I fixed that by gentle persuasion with a small 5 lb sledge. Yes, gentle. It is also possible that the bike itself is not perfectly symmetrical and that the 2mm/ 1/8" adjustment I needed to make is a function of the bike, rather than the bars, but the right angle tab on the bar was less than 90 deg inside. I'm open to all possibilities here.

I watched the OM videos for the crash bar and skid plate install several times, and made notes before I started. I, personally, was not impressed or satisfied with the video installation. Too many things mentioned in the early parts of the videos are information that you need later, such as torque numbers. Also, the foot pegs on the 850/ 900 GT need to be removed to get at the lower engine through bolt. The Rally foot peg mounts are different and that bolt is accessible. Also, the upper engine bolts, 14mm hex head, are very hard to actually reach. I did it, but it was not as easy or graceful as it is shown on the video. Overall, it took at least 4 hours, with pauses, and rewatching of the videos, and finding the necessary steps required for the non Rally models; that is the sort of thing that a piece of paper in the package should address. Also there are some very close fitment situations, where the front cross bar bolts are 3mm/ 1/4" from the plastics surrounding the radiator; a bit of movement there and the bar & bolts might damage the rad or plastic shroud. That is just speculation on my part, and it could be solid and reliable, based on the product design and testing.

After I had the bars installed, I went our for a trip of about 2000 kms, a week or so. Upon my return, I removed the upper crash bars so that the dealer would have an easier time accessing wiring to correct a problem with the heated grips they installed. I found the upper left crash bar bolt missing. Later, the shop discovered that the bolt was not missing, but had broken off inside the upper mounting hole. I was very careful with torque specs and no drops other than gentle let downs on sand to practice picking the bike up.

I like the Outback bar design, and the protection seems very good. I'm less impressed with the installation process and the instructions, and a bit concerned about the bolts and attachments, but I think that various bar makers use many of the same attachment points. The upper front engine mounts seem to be used by all.

I didn't notice any change in the vibrations with the bars, but I have grip puppies installed. The bike is vibey at certain speeds, so hard to tell if there was any change.

@flyingburritobrother , I watched your video on the H & B bar problems. Thanks very much for that clear and calm presentation.

 

[DamonYVR]

Hi @flyingburritobrother and thanks for the prompt and helpful reply. In order of your points, yes, it was the upper left engine head mount. The bolt broke 'inside' the head; far enough in that I could not see the broken end and so thought the bolt was missing altogether. Of my 2000 kms, none of it was rough off road. I've done an off road ADV training course (not on this bike) so I have some training and experience, but I also tend to ride alone and so I do not want to risk any sort of damage that would strand me, either through damage to me or the bike. Plus, I'm an Adenture-lite sort of rider. No crazy ascents or decent, and I go slowly. Nothing as rough or as fast as in your 'off the beaten path 2020' video. I could do that, I'd just go more slowly. I'll add a couple of pics of the off road I did. One forest service road, and part of the Kettle Valley Trail between Naramata and Kelowna, BC.

I want to stress that I am confident that I did not over tighten the upper engine / engine bar mounting bolts, as I am cautious (or fearful) about a stripped thread. Also, the engine parts are aluminum, which is almost certainly softer than the 10.8 bolt supplied by Outback Motortek. Because of the odd angle of extensions and swivel joints, and the poor visibility, I worked on these bolts very carefully. Actually, I was mostly worried about rounding off the lugs on the hex bolt head. And with the torque wrench, I must assume that the bolt was correctly torqued.

I have not actually spoken to OM about this. I had a few ... not terse, but careful emails with the company owner, very shortly after I had done the installation. I wrote to express my concerns, and my complaints, about about the fitment issue and the incompleteness of the instructions, especially as there is information applicable to installation on the 850 (and I think the 900 GT/ Pro). I was not asking for any compensation or replacement parts. His initial reply was that I had more complaints than they had ever had; that may well be true. I was disappointed, but we continued our exchange and I think we concluded on good terms. I don't want to repeat that conversation, as it can't help but be out of reasonable context for others.

I have not contacted OM or the owner; I could, but I don't want to create a new fuss that ends up with finger-pointing or some sort of circular mud fight. I guess I could post on the ADV rider forum but I really try to be clear, correct and fair in any sort of public place. That said, I do appreciate being able to share and learn on forums. Thoughts and advice welcome.

oops. forgot to attach photos. Pretty gentle stuff.

 

[choerenz]

Crash bars have been a bit of an interesting journey for me on the Tiger (mine is an 850) I ordered and received the Outback Motortek bars and skid plate for the T850. Delivery took about five or six weeks, but as noted, they are in high demand. That was not a serious issue for me.

I did the install myself, as I've done before on other bikes, and I've also done all the rack installs and centre stand installs. I'm not an especially skilled mechanic, but I do have the necessary tools including a click-type torque wrench. I work carefully and slowly.

I had some fitment issues with the right side upper bar; the right angle upper engine attachment tab was bent too far, and so it did not fit. I fixed that by gentle persuasion with a small 5 lb sledge. Yes, gentle. It is also possible that the bike itself is not perfectly symmetrical and that the 2mm/ 1/8" adjustment I needed to make is a function of the bike, rather than the bars, but the right angle tab on the bar was less than 90 deg inside. I'm open to all possibilities here.

I watched the OM videos for the crash bar and skid plate install several times, and made notes before I started. I, personally, was not impressed or satisfied with the video installation. Too many things mentioned in the early parts of the videos are information that you need later, such as torque numbers. Also, the foot pegs on the 850/ 900 GT need to be removed to get at the lower engine through bolt. The Rally foot peg mounts are different and that bolt is accessible. Also, the upper engine bolts, 14mm hex head, are very hard to actually reach. I did it, but it was not as easy or graceful as it is shown on the video. Overall, it took at least 4 hours, with pauses, and rewatching of the videos, and finding the necessary steps required for the non Rally models; that is the sort of thing that a piece of paper in the package should address. Also there are some very close fitment situations, where the front cross bar bolts are 3mm/ 1/4" from the plastics surrounding the radiator; a bit of movement there and the bar & bolts might damage the rad or plastic shroud. That is just speculation on my part, and it could be solid and reliable, based on the product design and testing.

After I had the bars installed, I went our for a trip of about 2000 kms, a week or so. Upon my return, I removed the upper crash bars so that the dealer would have an easier time accessing wiring to correct a problem with the heated grips they installed. I found the upper left crash bar bolt missing. Later, the shop discovered that the bolt was not missing, but had broken off inside the upper mounting hole. I was very careful with torque specs and no drops other than gentle let downs on sand to practice picking the bike up.

I like the Outback bar design, and the protection seems very good. I'm less impressed with the installation process and the instructions, and a bit concerned about the bolts and attachments, but I think that various bar makers use many of the same attachment points. The upper front engine mounts seem to be used by all.

I didn't notice any change in the vibrations with the bars, but I have grip puppies installed. The bike is vibey at certain speeds, so hard to tell if there was any change.

@flyingburritobrother , I watched your video on the H & B bar problems. Thanks very much for that clear and calm presentation.

Wow - so you had a similar bolt issue but with a different manufacturer. That is not encouraging. How did you fix the issue with the broken bolt? I had briefly looked at the SW Motech bars but felt that they may not protect the lower engine sufficiently. I'm really curious to hear what others have done to find a good solution that provides protection but not at the cost of vibrations or other issues.

 

[flyingburritobrother]

Beautiful pics and place to ride! You are very fortunate!

I agree with you on being clear, correct and fair in public boards. That is how I treated Motomachines/Hepco in the beginning. I was patient and respectful to them...even when they kept falsely claiming I "over tightened" the bolts (later disproved). It's only when the dishonesty started months later is what put me over the edge. Sadly, these message boards/forums are the only way the consumer can advocate for change through awareness.

My comment about sharing this elsewhere was not meant to slam Outback Motortrek in any way. It's more to just let people know to keep an eye on this particular mounting point. My bolts both broke off inside the frame itself. I still fear what damage may have been done to my bike with no front engine mounting support for who knows how long. I just don't want to see this happen to anyone else.

Hi @flyingburritobrother and thanks for the prompt and helpful reply. In order of your points, yes, it was the upper left engine head mount. The bolt broke 'inside' the head; far enough in that I could not see the broken end and so thought the bolt was missing altogether. Of my 2000 kms, none of it was rough off road. I've done an off road ADV training course (not on this bike) so I have some training and experience, but I also tend to ride alone and so I do not want to risk any sort of damage that would strand me, either through damage to me or the bike. Plus, I'm an Adenture-lite sort of rider. No crazy ascents or decent, and I go slowly. Nothing as rough or as fast as in your 'off the beaten path 2020' video. I could do that, I'd just go more slowly. I'll add a couple of pics of the off road I did. One forest service road, and part of the Kettle Valley Trail between Naramata and Kelowna, BC.

I want to stress that I am confident that I did not over tighten the upper engine / engine bar mounting bolts, as I am cautious (or fearful) about a stripped thread. Also, the engine parts are aluminum, which is almost certainly softer than the 10.8 bolt supplied by Outback Motortek. Because of the odd angle of extensions and swivel joints, and the poor visibility, I worked on these bolts very carefully. Actually, I was mostly worried about rounding off the lugs on the hex bolt head. And with the torque wrench, I must assume that the bolt was correctly torqued.

I have not actually spoken to OM about this. I had a few ... not terse, but careful emails with the company owner, very shortly after I had done the installation. I wrote to express my concerns, and my complaints, about about the fitment issue and the incompleteness of the instructions, especially as there is information applicable to installation on the 850 (and I think the 900 GT/ Pro). I was not asking for any compensation or replacement parts. His initial reply was that I had more complaints than they had ever had; that may well be true. I was disappointed, but we continued our exchange and I think we concluded on good terms. I don't want to repeat that conversation, as it can't help but be out of reasonable context for others.

I have not contacted OM or the owner; I could, but I don't want to create a new fuss that ends up with finger-pointing or some sort of circular mud fight. I guess I could post on the ADV rider forum but I really try to be clear, correct and fair in any sort of public place. That said, I do appreciate being able to share and learn on forums. Thoughts and advice welcome.

oops. forgot to attach photos. Pretty gentle stuff.

View attachment 758902 View attachment 758903

 

[Emgeesea]

I have the SW-Motech crash bars on my Rally, and have dropped the bike at low speed in dirt/gravel several times. The bars hold up well, and not a mark anywhere else on the bike, just on the bars themselves. (And a little on the SW-Motech hand guard frames.) I think combined with the heavy duty SW-Motech sump guard I have as well, the engine is pretty well protected.

 

[choerenz]

I have the SW-Motech crash bars on my Rally, and have dropped the bike at low speed in dirt/gravel several times. The bars hold up well, and not a mark anywhere else on the bike, just on the bars themselves. (And a little on the SW-Motech hand guard frames.) I think combined with the heavy duty SW-Motech sump guard I have as well, the engine is pretty well protected.
View attachment 759638

Was it necessary to add their bash plate or could you have kept the stock one? Also, have you noticed any incremental handlebar vibrations since you put these on?

 

[sherif]

Keeping an eye on this thread. I have the Hepco and Becker guards installed, but I've been debating a switch to SW Motech or Outback Motortek - last thing I want to deal with is some busted bolts in the engine mounts or headlight subframe. Sigh.

Also has anyone noted some annoying ass resonance from the bash plate? I saw in some KTM forums that people throw rubber or dynamat on the inside of the plate to reduce noise. Has anyone done that here?

 

[Emgeesea]

Was it necessary to add their bash plate or could you have kept the stock one? Also, have you noticed any incremental handlebar vibrations since you put these on?

I bought the bike with the SW stuff already installed, so have no basis for comparison versus stock. I will say the SW engine guard is much more robust than the OEM plate. And I don’t notice any handlebar vibration.

 

[DamonYVR]

Hi @sherif

I don't know anything abut the Hepco bars except what I've read. I did post about the Outback bars and skid plate, but I'll repeat briefly here. I had a some fitment issues with the OM bars on my Tiger 850, but was able to hammer out one bracket to make it work. Ofter that, no fitment issues. I did have an OM bolt break for the upper front left bar mount; this is a bolt that replaces the OEM bolt that supports the engine in this location- one on each side. I found the owner of Outback somewhat unsympathetic to the fitment and also to my complaints, or comments, about information missing from the installation videos. He never did respond to my email about the broken bolt. I contacted the dealer in Canada, and they were very nice and easy to get on the phone. They offered to send me a new bolt, but it turns out they don't have any in stock, and did not seem to know where to get one. That is a disappointment. As it sits now, my bike has been in the shop for almost two weeks, just waiting for a bolt. They are going to use a Triumph engine mounting bar bolt as they don't seem to be able to get the 10M x 67 bolt that the OM video identifies.

As to the capability of the OM bars, I've never tested them but I do think they are well designed and well made.

RE the skid pan, I think you can do the OM bars without the skid plate, but not the plate without the bars. I got lots of reflected noise, but I don't think that is unusual. I lined the pan with 'Hushmat' as it is available here and reasonably priced. It helps with the reflected mechanical clatter. But the larger windshield reflects engine noise as well, so I don't see that as a specific flaw of this product. I do think the OM skid plate mounting is good. Remove 4 screws and the plate comes off.

Here is a pic.

 

[sherif]

Hi @sherif

I don't know anything abut the Hepco bars except what I've read. I did post about the Outback bars and skid plate, but I'll repeat briefly here. I had a some fitment issues with the OM bars on my Tiger 850, but was able to hammer out one bracket to make it work. Ofter that, no fitment issues. I did have an OM bolt break for the upper front left bar mount; this is a bolt that replaces the OEM bolt that supports the engine in this location- one on each side. I found the owner of Outback somewhat unsympathetic to the fitment and also to my complaints, or comments, about information missing from the installation videos. He never did respond to my email about the broken bolt. I contacted the dealer in Canada, and they were very nice and easy to get on the phone. They offered to send me a new bolt, but it turns out they don't have any in stock, and did not seem to know where to get one. That is a disappointment. As it sits now, my bike has been in the shop for almost two weeks, just waiting for a bolt. They are going to use a Triumph engine mounting bar bolt as they don't seem to be able to get the 10M x 67 bolt that the OM video identifies.

As to the capability of the OM bars, I've never tested them but I do think they are well designed and well made.

RE the skid pan, I think you can do the OM bars without the skid plate, but not the plate without the bars. I got lots of reflected noise, but I don't think that is unusual. I lined the pan with 'Hushmat' as it is available here and reasonably priced. It helps with the reflected mechanical clatter. But the larger windshield reflects engine noise as well, so I don't see that as a specific flaw of this product. I do think the OM skid plate mounting is good. Remove 4 screws and the plate comes off.

Here is a pic.

View attachment 759731

Damon,

You rock. Thank you for sharing such informative photos and guidance. I'm concerned as to how these bolts keep breaking in the upper left - I wonder if the SW Motech avoids this by only mounting to the frame? I don't want to buy 3 sets of crash bars, 2 is good enough

That all said, I'm going to order some of that hush mat because my skid plate is driving me nuts. Thanks again for the tip.

 

[DamonYVR]

You're welcome. I like to help if I can, and I like the sharing of experiences and information. And I am totally on-siode about not wanting to buy 3 sets of every accessory. That is my usual routine with windshields. Lots of money in clear plastic.

The breaking bolts is a weird thing: it does not seem to be specific to one brand of bars. And several bar makers, including Triumph, use this same upper mounting point. I suspect we'll learn more about this as more Tigers spend time on the road, or on their sides.

The HushMat is just what I was able to find here. I bought a square, about 12" each side. Or was it two? Anyhow, it helps. The Dynamat may be better but I could not get it here and it is expensive. I wanted to get the mat on before my week away on the bike. It does help and takes the higher frequency rattling away to a large degree. Worth the $30 in my opinion.

One other thing, with the OM crash bars only installed, I'm not sure if the OEM plastic skid plate/ protector can stay on. I think it can, but the Outback skid plate attachment brackets do not allow for the OEM plastic plate to be put on. Says I, with about 80% certainty.

 

[Hawkbox]

Considering what I've seen of peoples crash bar stories and how you could write the bike off with them I think I'll just roll the dice on writing the bike off the old fashioned way.

 

[sherif]

Considering what I've seen of peoples crash bar stories and how you could write the bike off with them I think I'll just roll the dice on writing the bike off the old fashioned way.

but it looks cooler with protection that causes a write-off!

 

[flyingburritobrother]

Damon... Just read your response about Outback Motortrek.... that is VERY disappointing that they never responded to your email regarding the broken bolt. Chalk them up as another company I won't do business with.

I loathe companies who are quick to spout how great their products are, but don't give a crap about the customer when there are issues with the product down the road.

Best thing you can do...just keep letting people know what your experience with them was when the topic comes up. People can then decide if they want to do business with them being fully informed on how they treated you as a customer.

 

[Acook3]

Just wanted to say thank you all for your input in this thread. Hard to believe some of the stories about poorly made crash bars and mounting points. Based on your experiences. I think I will fit my Rally Pro with the SW-Motech crash bars and skid plate (know if I can find them in stock). They seem to leave the engine covers a bit more exposed compared to some, but I'd rather replace the cover than go digging for a sheared off bolt in the engine mount. I ride heavily off road; drops and spills are a common occurrence. Will let you know how it goes after a few crashes.

 

[choerenz]

Just wanted to say thank you all for your input in this thread. Hard to believe some of the stories about poorly made crash bars and mounting points. Based on your experiences. I think I will fit my Rally Pro with the SW-Motech crash bars and skid plate (know if I can find them in stock). They seem to leave the engine covers a bit more exposed compared to some, but I'd rather replace the cover than go digging for a sheared off bolt in the engine mount. I ride heavily off road; drops and spills are a common occurrence. Will let you know how it goes after a few crashes.

if you find any in stock let us know who has them.

 

[nateonator]

I've been very happy with the T-Rex Racing upper bars and skid plate. No increase in vibrations. I've tested the bars vs ground a few times off-road without issue as well. I suppose time will tell if I run into bolt issues. The T-Rex Racing upper bars are lighter and thinner than the competition and mount up a little differently too, which may be positive factors.

I did notice some increased noise from the skid plate, but this is very common with large plates. I sprayed the inside with rubber paint and that helped a lot. Hardly any additional weight added.

Sent from my Pixel 4 using Tapatalk

 

[9W6VX]

@DamonYVR,

I had the same concern with OM not replying to emails.

When I bought my 800XR in 2019, I researched crash bars and bash plates.
I shortlisted OM and Heed.
However when I contacted OM there was a initial email reply but after my second email they never bothered to reply. I remember sending friendly reminders but never got a reply.

I then contacted Heed in Poland and emails were replied quickly. The bonus was that Heed was cheaper than OM with shipping to Malaysia. Thus, I bought Heed.
I've dropped my bike a few times and the crash bars have done their part. I touched up the bars with black spray paint on the areas where the bars were badly scratched.
Bash plate is brilliant when compared to the skinny plastic thingy that came on my XR.

Over these 2 years I have heard the same pattern of no communication by OM on the forums.

Sorry to hear about the breaking bolts and hope you get it sorted soon.

☕

 

[DamonYVR]

Thanks @9W6VX

I really appreciate this post. I have not written a review of the OM bars, but I'll try and set aside some time tomorrow to do so. On one hand, I like the design and substantial construction of the OM bars; their videos aside, I do believe, based on looking at the bars on the bike, that they are well designed. I can't say that the bolt breakage is a fundamental flaw common to their parts, but I do think it is reasonable to have better communication. And I'd expect any company to be able to ship out any replacement parts promptly. I had a V-Strom previously, and I know that some V owners also had fitment issues, so I feel confident that my issue was not an isolated one.

During my initial email exchange with the owner, he asked why I didn't ask for a replacement bar for the part that didn't fit well. A fair question, but given that it takes 6-8 weeks to get them, I really didn't feel like waiting until the end of summer to get a replacement. And if they can't stock bolts, then how long would it take to get a whole new bar- a much more expensive and substantial part.

I'd love to be able to rave about the product and support; to have a good alternative to the expensive brands like SW and Altrider would be outstanding. And if there was a bolt in the mail to me right away, I would be hugely complementary. But that has not happened. Such a shame.

Good reputations are hard to build but easy to destroy. Regaining a good reputation is even harder. This evening, with my bike off the road for almost two weeks, I'm finding it hard to be complementary about the company.

 

[9W6VX]

@DamonYVR,

I agree with you mate.
☕