Tool for removing the Bar End Insert from Triumph handlebars (28.6 / 22 mm).

You only need an M6 bolt (minimum 40 mm long) and an M6 flange nut. If you print the tool from a more durable material, a washer will not be necessary. I printed it in PETG with 100% infill, and I added a washer just in case.

Instructions:

• First, remove the grips on both sides. At the end of the handlebar, you should see the retention pin. Using a small Torx or hex bit—or in my case a 1/8” roll pin punch—hammer the retention pin through.

• Thread the nut onto the bolt, then slide the bolt through the 3D-printed tool. Screw the bolt into the bar end insert as far as possible. Hold the bolt in place with an Allen key, and use a wrench to turn the nut clockwise to loosen the insert. The bar end insert should come loose immediately. No hammering or excessive force is required.