I would like someone to give me an idea of where I have gone wrong.

It took 5 tonne of pressure to press out the old bushings. Only 1 tonne to press the new bearings in.

The new bushings where from off the road.

The handlebars are wobbling worse than before.

There is a small gap between the bottom of the clamp and the top yolk plate.
Is that normal?
Finding it difficult to get any purchase on the nut that tightens everything up on the underside of the top yolk plate.

If I press the bushing down a little more should it make any difference? If i do the handlebar clamps will touch the top plate.

Any advice negative, or positive is welcome.

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I have no words of wisdom...

it's my guess the bar clamps shouldn't really be touching the top triple yoke's surface or you'd get all the vibrations back into the bars from the yolk. The bushings are to allow the bars to effectively 'float' by isolating the clamps (bolts) in the rubber tubing and therefore reduce the vibes. If you've got a depth gauge I'd measure the depth of the hole where the bar clamp bolt passes through and make sure the new ones are the same as the old in depth. As for pressure to insert the new sleeves, I would guess the old ones had a better 'tolerance' fit than the new or possibly had 'corrosion bonded' with the bush sleeves being steel and inserted into alloy. It's too late now, but I might have mic'd the o/s diameter of both the old and new before fitting too.

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I have a lot of growing up to do. I realized that the other day inside my fort.

Update:

I fitted the Off the Road rubber bushings as a replacement for the originals. They were worse than the originals. The bars moved around like mad. It was as if the rubber was really soft. I could not find a cure.

I decided to get a local engineer to fashion solid bushings and hey presto. Success..only time will tell if the vibration bothers me.

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I have no words of wisdom...