Handlebar Architecture: 7/8" Crossbar vs. 1-1/8" Oversized Tapered vs. Twin-Wall
Regardless of clamping diameter at the triple tree, every motorcycle handlebar tapers down to 7/8 inch (22.2 mm) at the outer grip ends so universal throttle tubes, clutch perches, and front brake master cylinders can mount properly. The structural difference lies in the center clamping zone and wall-thickness profile:
| Handlebar Type | Center Clamp Diameter | Structural Engineering & Flex Characteristics |
|---|---|---|
| Standard 7/8" Crossbar | 7/8 inch (22.2 mm) | Uniform 22.2 mm 7075-T6 aluminum tube reinforced by a bolted or clamped upper crossbar brace to prevent bending on hard landings. |
| Oversized Tapered (No Crossbar) | 1-1/8 inch (28.6 mm) | Computer-profiled variable wall thickness (~5.0 mm at the 28.6 mm clamp tapering to ~2.0 mm at the ends). Eliminates the rigid crossbar so the bar can flex micro-millimeters vertically to absorb square-edge chop and reduce forearm pump. |
| Oversized Dual-Tube (Twinwall) | 1-1/8 inch (28.6 mm) | Tube-within-a-tube aircraft aluminum construction (7010-T73 outer tube + ultra-high-tensile 7010-T6 inner tube + upper crossbar) engineered for maximum crash survival in Supercross and Rally competition. |
1. Decoding the 4 Handlebar Bend Measurements (in Millimeters)
- Width (Typically 795 mm – 815 mm): End-to-end horizontal span. Woods and singletrack riders often trim bars down to 775–785 mm using pre-marked cut rings to clear narrow trees.
- Height (Typically 82 mm – 99 mm): Total vertical distance from the bottom of the center mounting surface to the highest point of the bar tip.
- Rise (Typically 50 mm – 68 mm): Vertical distance from the center clamp up to the first upper bend before the grip taper begins.
- Sweep / Pullback (Typically 52 mm – 58 mm): Rearward angle from the center mounting axis back toward the rider's torso. Less sweep (`52–54 mm`) pushes the rider's elbows up into an aggressive attack position over the front wheel; more sweep (`56–58 mm`) provides a relaxed seated posture for trail riding.
2. Open Flag Roost Deflectors vs. Full-Wrap Barkbuster Handguards
- Open-Ended Flag Handguards (Motocross): Mount strictly to the inner handlebar next to the controls, leaving the outer grip ends completely open. Mandatory in closed-course motocross so a rider's wrist cannot get trapped inside a closed metal loop during a high-speed tumble.
- Full-Wrap Aluminum Bar Handguards (Enduro / Woods / Trail): Anchor at both the inner triple clamp/bar mount and the threaded outer bar end with a heat-treated aluminum backbone. Prevents tree impacts from snapping clutch/brake levers or crushing fingers in tight singletrack.
Shop Handlebars, Grips, Handguards & Levers
Upgrade your cockpit with oversized handlebars, lock-on grips, and folding levers in our Controls & Ergonomics Department.
