Installing crash bars on your Everyday Motorcycles Tiger 900 is an essential upgrade for riders seeking enhanced protection and peace of mind. Whether you’re tackling rugged off-road trails or navigating busy urban streets, crash bars serve as a robust shield that safeguards your bike’s engine, radiator, fuel tank, and other vulnerable components from damage during unexpected drops or collisions. Beyond protecting your motorcycle, crash bars can also provide an additional buffer to reduce rider injuries by preventing the bike from pinning your leg under its weight in a fall.

The Tiger 900, known for its versatility and adventure-ready design, benefits greatly from the added security of crash bars. Factory-installed engine guards on some models may offer limited protection, but aftermarket crash bars are often engineered to provide superior coverage and durability, tailored specifically to the Tiger 900’s frame and geometry. This guide will walk you through the entire installation process, covering everything from selecting the right crash bars to ensuring a secure, professional fit.

Why Install Crash Bars on Your Tiger 900?

Before diving into the installation steps, it’s worth understanding the key benefits that make crash bars a worthwhile investment:

  • Engine and Frame Protection: Crash bars absorb and distribute impact forces, preventing direct hits to critical parts like the engine cases, radiator, and frame tubes.
  • Reduced Repair Costs: Falling without protection can lead to expensive repairs or component replacements. Crash bars minimize damage, potentially saving you hundreds or thousands of dollars.
  • Enhanced Rider Safety: By keeping the bike from fully resting on the rider’s leg, crash bars can reduce injury risk during a fall.
  • Improved Bike Stability After a Drop: Crash bars help prevent the motorcycle from tipping completely, making it easier to pick up after a laydown.
  • Customizable Aesthetic: Many crash bars come in finishes like powder-coated black, stainless steel, or brushed aluminum, complementing your Tiger 900’s look.

Selecting the Right Crash Bars for the Tiger 900

Choosing the correct crash bars is critical to ensuring proper fit, function, and durability. Here are some factors to consider when selecting crash bars for your Tiger 900:

  • Compatibility: Ensure the crash bars are specifically designed for the Tiger 900 model year you own. Some kits differ based on variants (GT, Rally, Pro, etc.).
  • Material: Most crash bars are made from steel tubing, offering a balance of strength and weight. Stainless steel bars resist corrosion but may be pricier.
  • Design and Coverage: Look for bars that provide comprehensive coverage to the engine’s sides and, if possible, protect the radiator and lower frame.
  • Mounting Hardware: Reputable kits include all necessary bolts, spacers, and brackets for secure installation.
  • Finish: Powder-coated or ceramic-coated finishes offer durability and rust resistance.
  • Additional Features: Some bars come with integrated mounts for auxiliary lights or skid plates, which can be useful for adventure riders.

Tools and Materials Needed

Gathering the right tools before starting the installation will ensure a smooth and efficient process. The following items are typically required:

  • Crash bar kit: Specifically designed for the Tiger 900 and complete with mounting hardware.
  • Socket wrench set: Metric sizes compatible with your bike’s bolts.
  • Allen keys/Hex wrenches: For any hex bolts included in the kit.
  • Torque wrench: To tighten bolts to manufacturer’s specified torque values.
  • Thread locker (e.g., Loctite): Optional but recommended for securing fasteners against vibration.
  • Protective gloves: To protect your hands during installation.
  • Motorcycle stands (center or paddock stand): For stabilizing the bike during work.
  • Cleaning supplies: Degreaser and rags to clean mounting surfaces before installation.

Step-by-Step Installation Guide

1. Prepare Your Motorcycle

Start by parking your Tiger 900 on a flat, stable surface. Use a center stand or paddock stand to keep the bike upright and steady throughout the installation. This stability is crucial to avoid accidental tipping or movement while working.

Before touching any parts, make sure the engine is cool to prevent burns, and disconnect the battery’s negative terminal if you will be working near electrical components.

2. Remove Necessary Components

Depending on the crash bar design, you may need to remove side panels, engine guards, or other accessories to access the mounting points. Consult the crash bar kit’s instructions to identify which components need to be removed. Use the appropriate tools to carefully remove these parts, setting them aside safely for reinstallation.

Take photos during disassembly to help with reassembly later.

3. Clean Mounting Surfaces

Before installing the crash bars, clean the frame’s mounting areas with a degreaser and rag to remove dirt, grease, or rust. A clean surface ensures proper fitment and prevents hardware loosening over time.

4. Align the Crash Bars

With the help of a friend or using a bike stand, hold the crash bars against your Tiger 900, aligning the mounting holes with the bike’s frame brackets. This step may require some trial and error to ensure the bars fit flush without interference.

Check for proper clearance around exhaust pipes, footpegs, and fairings to avoid any rubbing or contact.

5. Secure the Bars Loosely

Insert the bolts provided in the kit through the mounting holes and thread them into the frame by hand at first. Do not fully tighten yet; allow some movement to adjust alignment as needed.

6. Tighten Bolts to Specification

Once all bolts are in place and the crash bars are properly positioned, use a torque wrench to tighten each bolt to the manufacturer’s recommended torque setting. Over-tightening can damage threads or warp the bars, while under-tightening risks loosening during rides.

If your kit instructions specify a sequence for tightening bolts, follow that carefully to maintain even pressure.

7. Apply Thread Locker for Extra Security

To prevent bolts from loosening due to vibration, apply a medium-strength thread locker to the threads before final tightening. This is especially important if you frequently ride off-road or on rough terrain.

8. Reinstall Removed Components

Reattach any side panels, engine guards, or other parts you removed earlier. Ensure they fit properly around the newly installed crash bars without pinching or interference.

9. Final Inspection

Perform a thorough inspection of all mounting points and fasteners to confirm everything is secure and tightened to spec. Gently try to move the crash bars by hand to check for any play or looseness.

Also, verify that there is adequate clearance around the exhaust, foot controls, and fairings to avoid chafing or damage during normal operation.

Post-Installation Tips and Maintenance

With your crash bars installed, your Tiger 900 is now better protected against damage from minor falls and scrapes. To maintain optimal performance:

  • Regularly Check Fasteners: Inspect all mounting bolts after your first few rides and periodically thereafter, especially following off-road excursions.
  • Clean the Bars: Keep the crash bars clean of dirt and debris to prevent corrosion. Use mild soap and water, and dry thoroughly.
  • Touch-Up Scratches: If the bars get scratched or chipped, apply touch-up paint to prevent rusting.
  • Use the Bars for Lifting: Some riders use crash bars as leverage points to lift the bike if it falls, but always lift carefully to avoid twisting the bars or frame.

Additional Considerations for Adventure Riders

If you frequently take your Tiger 900 on challenging terrains, consider these enhancements in conjunction with crash bars:

  • Skid Plates: Protect the underside of the engine and frame from rocks and impacts.
  • Auxiliary Lights: Mount lights on your crash bars for improved visibility during night rides or adverse weather.
  • High-Quality Mounting Hardware: Upgrade to stainless steel bolts and locking nuts for greater corrosion resistance.
  • Crash Bar Guards: Add rubber or plastic covers to your bars to reduce damage to your boots and clothing.

Conclusion

Installing crash bars on your Everyday Motorcycles Tiger 900 is a practical and valuable modification that enhances your bike’s durability and your own safety. By following this comprehensive guide, you can confidently fit crash bars that are securely mounted and tailored to your motorcycle’s specifications. Not only will these bars help protect your investment by minimizing damage from falls, but they also prepare your bike for the rigors of adventure riding and everyday commuting alike.

Remember, careful installation and regular maintenance of your crash bars will ensure they continue to perform effectively, giving you the freedom to ride with greater confidence wherever your journeys take you.