Help Please!
 

Hi all!

Got me some ufo handguards, went to fit them earlier but had trouble at the off. Removed the bolt but I couldnt get the flippin bar end off :062: I pulled, twisted, wiggled, jiggled all to no avail. It's like there's something holding it back and to top it off, I tried screwing the bolt back in but couldnt.

Sorry for the numnut question but I really could do with some advice. Fanks :)

Anybody?! I was hoping to get these sorted tonight as I've lost my winter gloves & my fingers were blue by the time I got to work :(

I know very little about those myself, all I know they are hard to remove, they are designed to expand and clamp in the bar when tightened but ideally when the long screw is removed they should pop out, try soaking them with WD40 and then get a long neck pliers and see if they give, alternatively tap the opposite end with a wood mallet and they should really come out. If not its going to be a run to your local friendly mechanic, I am afraid.

Yeah judging by the bits & pieces that came with the handguards I realised that there might be something expanding in there but I didnt want to force it too much in case I damaged something.

Are the two ends connected in some way?

No :076: :rotf[1]:

http://www.sp30.co.uk/images/smiles/moon.gif


:p

I'm going on a short Easter break to Galipolli on Friday, really could do with some info, otherwise its me vs. machine when I get home!!!

Hi Denny,

The bar ends are made of the solid end piece and a smaller piece that is pushed out by the bolt to wedge it inside the bar. You don't need to take the bolt all the way out, or the small bit gets left inside.

Unscrew the bolt until it goes a bit slack and you can withdraw it a little, then grab the bolt with some mole grips and wiggle the whole bar end assembly free. It shouldn't be too hard.

Storm

Thanks for the reply Storm!

I have already removed the bolt on the left side and have pulled/twisted the bar end quite a bit. I then tried to put the bolt back in and tighten, but it didnt want to rethread/connect.

I'm a bit worried that I've left the little bit inside now, as I'm assuming thats what the bolt threads onto :(

Should I just keep pulling the bar end until its off & then attempt to remove the little bit afterwards?!

Thanks mate ;)

OK, sounds like you've done what I did when I changed my bars... The little bit inside may have got wedged at an angle, meaning it won't rethread or withdraw. The bar end should just come off if the bolt is out. Try inserting a screwdriver in the bolt hole on the bar end and wiggling it like a mentalist - It should come out (it may have a thin layer of glue or threadlock).
Once the bar end is off, shine a torch down the bar and see if you can see the smaller bit. It may just have pushed out of reach of the bolt thread... in which case, fish it out with a straighened wire coat hanger (worked for me!!!).

Storm

So all is not lost then :)

Thanks mate :thumbsup: hopefully will have it sorted tonight :)

Any joy Denny?

Yes mate, all went well :023: I did as you said & unscrewed the bolt only slightly & it came out smooth. The first one I had to cut away from the grip as it had also been glued with some sort of industrial super glue :laughing11: Also had to cut a bit off the guard for a flush fit with the brake resevoir!

Some pics here...

http://www.xt660.com/showthread.php?t=2487