Split bars !

[rossguzzi]

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 !!

[buzybraza]

Do not fix your handlebar! Replace it!

[KTMbageera]

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.

[jas123]

Originally Posted by buzybraza

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.

[Kyler]

get a tap and do the threaded bar end trick. That won't happen again.

[rossguzzi]

Not sure what this bar end trick is?

[Kyler]

Originally Posted by rossguzzi

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.



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