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Handlebar replacement

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clarkeb
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Joined: 21 Aug 2017
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PostPosted: 12:26 - 21 Oct 2017    Post subject: Handlebar replacement Reply with quote

I bought heated grips but the screws on for the weights on the handlebars won't budge. I've tried using the reverse thread screw removers but with no luck.
It was suggested that it might just be easier to replace the handlebars which seems fairly straightforward.

However, looking at the schematics for the bike - photo attached, there seems to be more components for the internals than i would have thought...
Am i just able to buy a handlebar and end weights and do a straight swap?...

Cheers!
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Rogerborg
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Joined: 26 Oct 2010
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PostPosted: 12:37 - 21 Oct 2017    Post subject: Reply with quote

I had to use an impact screwdriver to shift mine.

This:

https://i.imgur.com/nBYimYo.png

You 'it it wiv an 'ammer.
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clarkeb
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PostPosted: 12:39 - 21 Oct 2017    Post subject: Reply with quote

I tried an impact screwdriver as well but nothing. Im guessing its just rusted inside so much it won't budge.
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clarkeb
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PostPosted: 13:05 - 21 Oct 2017    Post subject: Reply with quote

Ive given up on the screws anyway as the remover tools didn't work. I just wanted to know about the handlebars and if i can just swap them and get new end weights.
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Rogerborg
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PostPosted: 13:43 - 21 Oct 2017    Post subject: Reply with quote

Sure, you can swap them, they're just a bent piece of steel or alloy yes I know steel is an alloy.

However, I'd put PlusGas down those screws, torch them, give them some flat-on whacks, round them off with the impact driver, hammer them flat again, then round them off a 2nd time... then drill the heads off and get grips on the stubs.

Easier replacing a couple of screws (or replace them with bolts) than bars and weights.
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ZaphodBeeble
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PostPosted: 02:22 - 25 Oct 2017    Post subject: Reply with quote

On either end of those bars there are holes facing upwards and maybe downwards (you can see them in the schematic). The bar end weights have clips that slot into those holes to stop them falling out. The screw in the bar end doesn't technically hold them in. If you can peel the clutch side grip back you may be able to push the clip in and slide the bar end out. Then do the same thing on the throttle side. You'll have to slacken the throttle and front brake lever assemblies to slide them off the hole though.
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Islander
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PostPosted: 08:50 - 25 Oct 2017    Post subject: Reply with quote

ZaphodBeeble wrote:
On either end of those bars there are holes facing upwards and maybe downwards (you can see them in the schematic). The bar end weights have clips that slot into those holes to stop them falling out. The screw in the bar end doesn't technically hold them in. If you can peel the clutch side grip back you may be able to push the clip in and slide the bar end out. Then do the same thing on the throttle side. You'll have to slacken the throttle and front brake lever assemblies to slide them off the hole though.


Eh?

Every single bar end weight I've seen uses an expanding plug to hold it in - tightening the bolt pulls a tapered section into the plug which opens it up and causes it to grip the inside of the bars. These look no different.

The bolt is usually loosened and then tapped to drive the taper out of the plug to free the weight for removal. If the bolt won't move then an impact driver (as previously suggested) should get it on it's way.
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ZaphodBeeble
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PostPosted: 15:05 - 25 Oct 2017    Post subject: Reply with quote

Islander wrote:


Every single bar end weight I've seen uses an expanding plug to hold it in - tightening the bolt pulls a tapered section into the plug which opens it up and causes it to grip the inside of the bars. These look no different.


You haven't seen them all then.
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Suntan Sid
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PostPosted: 16:10 - 25 Oct 2017    Post subject: Reply with quote

ZaphodBeeble wrote:
On either end of those bars there are holes facing upwards and maybe downwards (you can see them in the schematic). The bar end weights have clips that slot into those holes to stop them falling out. The screw in the bar end doesn't technically hold them in. If you can peel the clutch side grip back you may be able to push the clip in and slide the bar end out. Then do the same thing on the throttle side. You'll have to slacken the throttle and front brake lever assemblies to slide them off the hole though.


This is correct!

Changed the end weights on my old CBR600 and they were as described above!
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Islander
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PostPosted: 16:19 - 25 Oct 2017    Post subject: Reply with quote

ZaphodBeeble wrote:
Islander wrote:


Every single bar end weight I've seen uses an expanding plug to hold it in - tightening the bolt pulls a tapered section into the plug which opens it up and causes it to grip the inside of the bars. These look no different.


You haven't seen them all then.


I hadn't claimed to have. Razz

I did however base my statement on the parts diagram but I'm always willing to learn something new. Very Happy
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Matt B
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PostPosted: 16:31 - 25 Oct 2017    Post subject: Reply with quote

Some bars have a threaded section welded into the inside of the bar.
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ZaphodBeeble
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PostPosted: 17:59 - 25 Oct 2017    Post subject: Reply with quote

Islander wrote:
I did however base my statement on the parts diagram but I'm always willing to learn something new. Very Happy


Just to clarify, the two number 8's are actually pieces of rubber to keep the weight (no. 6) central. The clip I mentioned is no. 9 which has the tangs on it that can be pushed in to slide the entire weight assembly out.
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Commuter_Tim
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PostPosted: 20:22 - 25 Oct 2017    Post subject: Reply with quote

Looks like an identical parts diagram to the CB500.

Expect that number 9 might rip it's tangs off if you finally get the weight out.

Granted I've only taken out 3 sets of rusted bar weights, but no amount of tapping in the tangs with a punch and twisting out would stop them contorting for me.
I was dealing with considerable rust though.

Number 8 could also be perished/broken.
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