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Old 03-03-2013, 12:06 AM   #1
rossguzzi OP
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Joined: Oct 2012
Location: Bottom left hand side of OZ
Oddometer: 699
Split bars !

I thought my throttle was getting a little hard to turn/return. So I loosened the end bolt that secures the guard and tried to get a little light lube inbetween the bar and the throttle tube. Then I did up the guard bolt. Problem. The throttle stuck. Turns out the bar has a split and when I tighten the bolt in the end of the bar for the guard, it expands the bar inside the throttle tube !!

Has anyone ever seen this before? I have not.
I did not over tighten the bolt at all. So some gorilla has worked on this bike at some stage.
I havnt taken it apart yet. Im hoping I can get a small weld on the outside of the bar along the split and grind back.

The things you find !!
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Old 03-03-2013, 12:42 AM   #2
buzybraza
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Do not fix your handlebar! Replace it!
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Old 03-03-2013, 06:48 AM   #3
KTMbageera
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Replace is right. Fatigued bars for whatever reason should not be trusted.

Treat yourself BIG and put a set of Flexx Enduro hi 15 degree bars. You will never go back.
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Old 03-03-2013, 07:04 AM   #4
jas123
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Quote:
Originally Posted by buzybraza View Post
Do not fix your handlebar! Replace it!
What he said, don't do it! Even if you are a competent welder. The type of aluminum usually used should not be welded. You may be able to physically weld it , but the bar strength, will be seriously compromised. Most likely very brittle at and around the weld.
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Old 03-03-2013, 08:07 AM   #5
Kyler
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get a tap and do the threaded bar end trick. That won't happen again.
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Old 03-03-2013, 06:35 PM   #6
rossguzzi OP
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Not sure what this bar end trick is?
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Old 03-04-2013, 05:36 AM   #7
Kyler
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Originally Posted by rossguzzi View Post
Not sure what this bar end trick is?
Thread the end of the bars, install an insert, screw into the insert. The typical insert wedges in place and causes the bar to bulge or split. This is a much more solid and secure mount.



http://www.brpmoto.com/index.php?pag...mart&Itemid=49
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Old 07-21-2013, 09:33 AM   #8
charlie264
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I replaced my standard bars for RC High Fat Bars on my KTM 950 SE. I also fitted heated grips and Acerbis RALLY PRO X-STRONG hand guards….I notice yesterday that the left hand guard was loose…
The reason the hand guard was loose is because the Fat Bar has split in two under the grip.
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Old 07-21-2013, 12:03 PM   #9
desert sky
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Quote:
Originally Posted by Kyler View Post
Thread the end of the bars, install an insert, screw into the insert. The typical insert wedges in place and causes the bar to bulge or split. This is a much more solid and secure mount.



http://www.brpmoto.com/index.php?pag...mart&Itemid=49
Thanks for this. I didn't know such stuff existed. Makes all the sense in the world. Should work on the sno-go's as well.
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Old 07-21-2013, 12:15 PM   #10
Peanuts
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I wonder how easy it is to drill and tap a grubscrew like thay have done? Thought it would be quite hard steel.......
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Old 07-21-2013, 01:12 PM   #11
charlie264
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Originally Posted by Peanuts View Post
I wonder how easy it is to drill and tap a grubscrew like thay have done? Thought it would be quite hard steel.......
You can buy um....Ive got some for wood but they are to big and the thread is like a wood screw. I'm going to try fasteners shop tomorrow.
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Old 07-22-2013, 01:13 PM   #12
Peanuts
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I have ground the corners off an M8 long nut in the past, then bashed it into the bar with a smear of bearing retainer.

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Old 07-22-2013, 02:18 PM   #13
charlie264
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Quote:
Originally Posted by Peanuts View Post
I have ground the corners off an M8 long nut in the past, then bashed it into the bar with a smear of bearing retainer.

I thought of using a die on one....then tapping the bar.
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