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Changing my handlebars from stock (steel) to thick walled 7/8" aluminum. Didn't go fat bat yet trying to keep things simple. But what happens to the inserts for my acerbis brush guards? Do they remain forever in the old bars one-time use only?

And for these thick walled aluminum bars do I need a special small diameter acerbis replacement insert? These Tag X-5 bars have a much smaller hollow area inside.

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Wish I had an answer for you. I can't get the inserts out of my old bars either!

In my experience, there are different bat end fittings, depending on which bars you use

I usually run pro taper bars with Accerbis hand guards. I feel like I've always had to drill out the bar ends a bit in order to get the bar end fittings to fit in.

For the bar end insert in your current bars, it should come out. I usually thread the adjuster bolt out a whole bunch, then give it a firm push in and it will break the clamp loose (if that's what your problem is). Or you can always get replacement bar end inserts off ebay.

Thanks, Tyl3r. Just the tip I was looking for. I'll give it a try to loosen the insert.

No problem! I've had to hit that bolt with a hammer before to break it loose

Mine look like welded threaded inserts as an integral part of the steel bar ends. Weird. Tossing the old bars and ordered 13.5mm acerbis inserts for aluminum bars from motosport. For $8 each, may be a safer bet to do it right.

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To get the inserts out, i used a washer that is bigger than the bar ends and with a center hole where i could fit the bolt through(or a longer bolt with the same threads, if you pushed it to deep)
Than start screwing the bolt in and the insert comes out