Bent Handlebar (MOT fail) - Stuck

[olionel]

Hello;

Posted this on the zxr400 forums aswell, got two replies basically saying "bash it out of place". But I think I am either being a sissy or there is something I am missing.

It appears that the physical steering stop (shown on image below) is very very slightly bent but straightening is not going to fix "trapping my thumb at full lock" problem. I think the handlebar its self is a lil bit bent too

https://i4.photobucket.com/albums/y113/mr-scientist/p1.jpg



So in order to straighten the handlebar itself I took the break lever off, the switches and throttle cable assembly off. Undid bolt 92150A (in big red circle) but the bar (46003A) seems to be physically restricted by a pin or something. There is a small pin underneath that stops me from rotating it. But is not designed to stop me from pulling it out as it has a slit where it's meant to slide out. I can pull the bar out about 5mm max then it stops.. something is not letting it move any further. On the diagram it does not show a physical restraint inside 46012A or on 46003A. What am I doing wrong? Is my easiest option undoing 92150 then looseining 120 spinnig round and re-nip it again leaving 92150 out? Is leaving out 92150 safe ???? (doubt it is..just pushing my luck)

https://i4.photobucket.com/albums/y113/mr-scientist/p2.jpg

I took out the main bolt of the other side too (that is not bent) too and the bar gets stuck around the same distance and will not budge. I wonder if the small pin that is stopping it from rotating is causing a physical block...

Thanks for your help in advance!
Oli
____________________
1989 CG125 - Childhood Sweetheart (she got kidnapped by baddies)
1998 ZXR400 - Teenage Love (lasted three years, then she turned lesbian and left me)
2001 XRV750 - Wife Material (still getting to know her but head over heels in love)

[Kickstart]

Hi

92150 is there to stop the bar clamp rotating around the fork. However plenty of bikes do without such a locating point (my Bimota hasn't for example, and most after market clip ons will also do without it).

It is possible that 92150 itself is bent and holding the clip on in the wrong position.

With the bar not coming out, it might be that it has a slight taper to hold it in place, and so needs a fair bit of force to push it back out.

All the best

Keith
____________________
Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[stinkwheel]

Or epoxy a bit of metal to the lock stop in question and paint over it .
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[olionel]

[Kickstart]

Hi

Rather than trying to twist the bar out, can you push it out? Have 92150A in position but loose and push that to push the bar out.

All the best

Keith
____________________
Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[olionel]

yes I will give that a go. I might try get hold of a longer M10 bolt and try using that to push it out with plenty of thread in so I don't damage the thread of the bar itself... thanks for the idea.
____________________
1989 CG125 - Childhood Sweetheart (she got kidnapped by baddies)
1998 ZXR400 - Teenage Love (lasted three years, then she turned lesbian and left me)
2001 XRV750 - Wife Material (still getting to know her but head over heels in love)