V85 crash bar install issues

[CanonVanagon]

Picked up a 2025 V 85 a couple weeks ago. I ordered the OEM crash bars and went to install them yesterday. It started out pretty easy but then when I got to the final Bolt in front of the bike by the horn. I was unable to thread the bolt by hand.  So I looked in the hole and the first few threads look nonexistent.  I’m gonna maybe try a thread chaser and if that doesn’t work, I guess a tap unless someone has some better ideas.

[CanonVanagon]

Got it taken care of with a Lang thread chaser kit off Amazon with a long 1/4 extension and ratchet

[Wallowa]

Why were threads missing?  What size tap did you use?

Thanks..Phil

[CanonVanagon]

Why were threads missing?  What size tap did you use?

Thanks..Phil

I'm not sure if was from when they welded the nut to the frame. It didn't look like powder coating to me. I decided to use a thread chaser instead of a tap. The size was a M8 1.25.

[Roman Hordan]

Glad you got it sorted. Worth knowing that welded-in nuts like that often have weld spatter or paint/e-coat sitting in the threads, so it's not unusual on a brand new frame. A chaser was the right call over a tap since it cleans up the existing thread rather than cutting new metal.

Before you torque that bolt down, I'd put a dab of anti-seize or a little grease on it. That nut is behind the horn area where it sees road spray, so it'll be much easier to remove next time you pull the bars off.

[JHBettsSr]

Picked up a 2025 V 85 a couple weeks ago. I ordered the OEM crash bars and went to install them yesterday. It started out pretty easy but then when I got to the final Bolt in front of the bike by the horn. I was unable to thread the bolt by hand.  So I looked in the hole and the first few threads look nonexistent.  I’m gonna maybe try a thread chaser and if that doesn’t work, I guess a tap unless someone has some better ideas.

My 2025 V85TT came with the OEM crash bars already installed. After taking delivery, I noticed the crash bar mounting bolt by the horn (RH side) was not screwed in all the way. Upon inspection I found the mounting bolt was cross threaded into the frame. Like you, I also had to re-tap the frame threads (and replace the mounting bolt).

[Bulldog9]

When I installed the Isotta crash bars, I had the same problem. The threads were there, but coated with the powdercoat or paint.