Removing bar ends

jax · February 20th, 2011, 05:09 PM

Anyone have a problem removing the stock bar ends ? I got some new ones with allen head screws with my slider kit but I can't get neither screw to beak loose on the stock ones. I even tried a impact tool you hit with a hammer and all I have done is buggered up the screws so bad I don't think anything will do it now

bob706 · February 20th, 2011, 05:19 PM

Heat the screw up with a butane torch for a few minutes then take the impact tool or drill to the screw. Should come right out, just be careful cause it will be friggin hot

jax · February 20th, 2011, 05:21 PM

I'll give that a try thx

kkim · February 20th, 2011, 05:35 PM

http://www.ninjette.org/forums/showthread.php?t=12960

scroll down to post #2.

TedBull · February 20th, 2011, 06:07 PM

I used a cutoff wheel on my angle grinder and cut into the end of the bar end and thru the bolt then the bar ends fell off and I used vice grip pliers to pull out the bolt stud. I did not want to put heat to it and the stock bar ends seemed useless to me so I did not care about damaging them. I ordered new heavy barends and love them.

http://www.amazon.com/Kawasaki-Heavy.../dp/B003V12XSW

They are inexpensive, great quality, much heavier than stock and beefy. Also I was able to add washers to the inside of the bar end to get the desired space between the bar end and my heated grips.

slolane · February 20th, 2011, 07:20 PM

Torch for about 1-2 minutes a side worked for me too and as noted above it will be very hot so be careful. After heating I was able to easily use screwdriver to remove.

nexus · February 21st, 2011, 09:44 PM

Only heat the screw head, not the entire bar end.Otherwise you might melt your grips.

It amazes me that Kawasaki is so liberal on red loctite for the bar end screws, but much more important fasteners on the bike have none.

setasai · February 21st, 2011, 10:02 PM

Quote:

Originally Posted by TedBull

I used a cutoff wheel on my angle grinder and cut into the end of the bar end and thru the bolt then the bar ends fell off and I used vice grip pliers to pull out the bolt stud. I did not want to put heat to it and the stock bar ends seemed useless to me so I did not care about damaging them. I ordered new heavy barends and love them.

http://www.amazon.com/Kawasaki-Heavy.../dp/B003V12XSW

They are inexpensive, great quality, much heavier than stock and beefy. Also I was able to add washers to the inside of the bar end to get the desired space between the bar end and my heated grips.

I dont suppose we could get a photo of the bar ends on the bike. They look like they're tapered differently than stock.

dyeforever · February 21st, 2011, 10:18 PM

I used a ratchet with a #2 Phillips bit and it came right off.

TedBull · February 21st, 2011, 10:21 PM

Quote:

Originally Posted by setasai

I dont suppose we could get a photo of the bar ends on the bike. They look like they're tapered differently than stock.

I will get one for you tomorrow. They are the same diameter of the grip at the grip and then taper down a little, but look good IMO. They are a huge improvment over stock as they are beefy and heavy to reduce vibration. And come with a allen head bolt.

lunerkid · February 22nd, 2011, 01:09 AM

I used a butane torch.

As someone said, make sure it is just the bolt otherwise you might start cooking your grips.

Afterwards screws come of really easy.

TedBull · February 22nd, 2011, 01:25 AM

Quote:

Originally Posted by lunerkid

I used a butane torch. As someone said, make sure it is just the bolt otherwise you might start cooking your grips.

Yes, or worse cooking your throttle tube. Here are some pics of the $30 heavy bar ends and another link to them.

http://www.amazon.com/Kawasaki-Heavy.../dp/B003V12XSW

gfloyd2002 · February 22nd, 2011, 03:54 AM

Jax, you aren't alone. Before I realized there was locktite in there, I mangled my bar end screws when I tried to take them off to change grips. Ended up using a little chisel to remake and deepen the mangled screwdriver hole for better grip, heating up the ends with a soldering gun to release the locktite, then used a ratchet attachment on the screwdriver. I destroyed the screws and had to replace them, but they came out.

If I had to do it again, I'd have gone straight to the soldering gun or torch and used an impact wrench. (I chose the soldering gun last time to localize the heat to the screw and protect the grips and throttle tube.) Locktite melts at 400 degrees and lubes the screw, so heat is really the way to go. Would have been able to save the screws that way. Also, if I had to do it again I would have switched out to the heavier bar ends with the allen head screws seen below. Allen head screws should have come standard on the bike if they are going to use locktite.

Good luck.

jax · February 22nd, 2011, 05:40 PM

I will try all of the above this weekend

--- thankx

BTW, I guess I need to post up some pics soon of the Black one in the garage next to the Green slower one

and here I am talking bad about green

when I have lots of Kawi green shirts plus a 12 ft Green Kawasaki banner in my garage as well as Kawi streamers hanging from the ceiling

sorry Greenie owners, my bad LOL

austexjg · February 22nd, 2011, 05:45 PM

One screw of mine is also stripped - tried to remove before finding the site. Have the screw, but have not had no desire to try to remove the messed up screw after yelling at it back then...

kkim · February 22nd, 2011, 07:23 PM

Quote:

Originally Posted by jax

BTW, I guess I need to post up some pics soon of the Black one in the garage next to the Green slower one

CZroe · February 22nd, 2011, 08:28 PM

Quote:

Originally Posted by kkim

Fortunately, Commodus' opinion ultimately didn't matter much.

slolane · February 22nd, 2011, 08:31 PM

LOL, that's funny! But kkim is right, green is faster!

setasai · February 22nd, 2011, 09:18 PM

Quote:

Originally Posted by TedBull

I will get one for you tomorrow. They are the same diameter of the grip at the grip and then taper down a little, but look good IMO. They are a huge improvment over stock as they are beefy and heavy to reduce vibration. And come with a allen head bolt.

Cool. They look good. If i ever end up needing bar end replacements, i'll definitely pick up a pair of these. The other ones I've seen online are like $60 a pair.

I just used my mom's creme brule butane torch. Worked like a charm.

jax · February 23rd, 2011, 03:43 PM

Quote:

Originally Posted by slolane

LOL, that's funny! But kkim is right, green is faster!

haha

color don't matter much here on the roads of East TN and W NC.... The Dragon and the Cherohala and the Blue Ridge don't care what color it is just as long as you ride and enjoy

CZroe · February 24th, 2011, 11:18 PM

Quote:

Originally Posted by kkim

funny-car-photos-i-am-spartacus.jpg

Cha0s00100 · February 28th, 2011, 03:52 PM

I used a #3 and it came off . . although it did break the bit . . lol. I did it in -3deg c weather though possibly why the btt broke. Used the #2 to finish the job. Did a number on the screw, may oped to change the screw down the road.

Quote:

Originally Posted by dyeforever

I used a ratchet with a #2 Phillips bit and it came right off.

Aggrotech · July 4th, 2013, 12:57 PM

RISE OLD THREAD!

Are there any new methods to removing the bar ends? Dont have an impact gun or heat gun, so i just used a massive bbq lighter and heated the bolt for about 4 minutes, tried, failed..and continued to 10 minutes. could definitely feel the heat when i put my hand on the grip..but to no avail. I know theres a good gallon of red loctite or so on them and ppl seem to get it with a heat gun, but no matter which method or tool i use, it wont budge..not even an inch.

bkh2 · July 4th, 2013, 01:26 PM

I used a propane torch (jet lighter would work too). I found that I had to tap the bolt with a hammer several times (and by tap, I mean put some effort into it, but don't go overboard). It should be fairly easy to remove the bolt after that.

Dark · July 4th, 2013, 01:28 PM

I used a porter cable impact drill and a large Philips bit, both came off in seconds.

One can also use a Philips socket on a long ratchet, just keep pressure against the socket and screw.

Aggrotech · July 4th, 2013, 01:42 PM

Ive tried all the methods in this thread other than the impact gun and obviously drilling the head off. I have a feeling im gonna have to completely destroy them to get them off, just like i did with my oil bolt >_>.

choneofakind · July 4th, 2013, 01:42 PM

Skip all the hassle.

1/4" drill bit and 60 seconds of your time, and that bar end will be off.

Aggrotech · July 4th, 2013, 02:37 PM

Quote:

Originally Posted by choneofakind

Skip all the hassle.

1/4" drill bit and 60 seconds of your time, and that bar end will be off.

funny you say that, thats exactly what i just did. Still not out though

Aggrotech · July 4th, 2013, 06:01 PM

i have done it! 16threads of red locktight.... was also heating the bolt throughout the day....that was fckn ridiculous. F u kawi!

Ktam · July 4th, 2013, 06:05 PM

Quote:

Originally Posted by Aggrotech

i have done it! 16threads of red locktight.... was also heating the bolt throughout the day....that was fckn ridiculous. F u kawi!

Well sounds like you've got the head drilled out. I would've highly recommended this bad boy:

http://2.bp.blogspot.com/_3MANcVjKs7...20/10cr_lg.jpg

Grab that sucka and twist it out!

subxero · July 4th, 2013, 06:06 PM

i got mine out with just a 1/4inch driver and a phillips screw head attachment, sure i broke 2 phillips head bits before i got the one out but they were cheaper bits

Aggrotech · July 4th, 2013, 06:12 PM

Quote:

Originally Posted by Ktam

Well sounds like you've got the head drilled out. I would've highly recommended this bad boy:

http://2.bp.blogspot.com/_3MANcVjKs7...20/10cr_lg.jpg

Grab that sucka and twist it out!

thats what i used after i got the head off, tried it without heating and it still did not budge, no matter how hard i tried. about 85% of the threads were full red locktight lol..dont think ive ever seen so much before o.o

sadly my new bar ends dont fit. Rojo tried to warn me but it was too late

Ktam · July 4th, 2013, 06:17 PM

Quote:

Originally Posted by Aggrotech

thats what i used after i got the head off, tried it without heating and it still did not budge, no matter how hard i tried. about 85% of the threads were full red locktight lol..dont think ive ever seen so much before o.o

sadly my new bar ends dont fit. Rojo tried to warn me but it was too late

Sloppy joe must've applied yours at the factory. BTW I recommend using blue loctite and some stainless steel hex bolts for your replacement. Them bar ends are heavy window smashers.

choneofakind · July 4th, 2013, 07:00 PM

Yeah they use tons of red locktite there. I drilled the heads on mine, still haven't gotten the shaft of the screws out

Slick_Stevo · July 5th, 2013, 08:22 AM

Quote:

Originally Posted by choneofakind

Yeah they use tons of red locktite there. I drilled the heads on mine, still haven't gotten the shaft of the screws out

Strange...mine came right off with no issues...phillips head on a ratchet

choneofakind · July 5th, 2013, 12:56 PM

Yeah well, I don't have the phillips head attachment for a ratchet, but I have a drill and drill bit, so it was cheaper and easier to just drill it since I went with WC bars anyways.

crazymadbastard · July 6th, 2013, 10:07 AM

Mine came out after some pounding with a manual impact driver and then used the bit on a ratchet.

ChickenRun · July 7th, 2013, 02:55 PM

After going to home depot to buy one my drill bit snapped while trying to drill that dang screw out. I got so pissed I smacked it with a rubber hammer and the head popped right off.

Ktam · July 7th, 2013, 03:08 PM

Quote:

Originally Posted by ChickenRun

After going to home depot to buy one my drill bit snapped while trying to drill that dang screw out. I got so pissed I smacked it with a rubber hammer and the head popped right off.

Did you use a cobalt or HSS bit? That's pretty damn impressive to break the bit like that...the oem screw was pretty soft. Maybe you applied pressure some pressure in the wrong direction?

ChickenRun · July 7th, 2013, 04:23 PM

Quote:

Originally Posted by Ktam

Maybe you applied pressure some pressure in the wrong direction?

That. I had already spent the whole day trying different strategies to get the bolt off, so I was pretty frustrated.

February 20th, 2011, 05:09 PM	#1
jax Lifelong Rider Name: Jack Location: East Tennessee Join Date: Apr 2009 Motorcycle(s): mine-> '04 Kawasaki Vulcan 1600,'08 Ninja 250 / hers-> '05 Kawasaki Vulcan 800, '08 Kawasaki Ninja 250 Posts: 29	Removing bar ends Anyone have a problem removing the stock bar ends ? I got some new ones with allen head screws with my slider kit but I can't get neither screw to beak loose on the stock ones. I even tried a impact tool you hit with a hammer and all I have done is buggered up the screws so bad I don't think anything will do it now __________________________________________________ Jax Kingston TN '04 Kawasaki VN1600 '08 Ninja 250

February 22nd, 2011, 03:54 AM	#13
gfloyd2002 User Title Free Since '12 Name: Floyd Location: Barbados Join Date: Dec 2010 Motorcycle(s): '10 Ninja 250R Special Edition Green Posts: A lot. Blog Entries: 13 MOTM - Feb '12	Jax, you aren't alone. Before I realized there was locktite in there, I mangled my bar end screws when I tried to take them off to change grips. Ended up using a little chisel to remake and deepen the mangled screwdriver hole for better grip, heating up the ends with a soldering gun to release the locktite, then used a ratchet attachment on the screwdriver. I destroyed the screws and had to replace them, but they came out. If I had to do it again, I'd have gone straight to the soldering gun or torch and used an impact wrench. (I chose the soldering gun last time to localize the heat to the screw and protect the grips and throttle tube.) Locktite melts at 400 degrees and lubes the screw, so heat is really the way to go. Would have been able to save the screws that way. Also, if I had to do it again I would have switched out to the heavier bar ends with the allen head screws seen below. Allen head screws should have come standard on the bike if they are going to use locktite. Good luck. __________________________________________________ "Improvement makes straight roads, but the crooked roads without improvement, are roads of genius." — William Blake

February 22nd, 2011, 05:40 PM	#14
jax Lifelong Rider Name: Jack Location: East Tennessee Join Date: Apr 2009 Motorcycle(s): mine-> '04 Kawasaki Vulcan 1600,'08 Ninja 250 / hers-> '05 Kawasaki Vulcan 800, '08 Kawasaki Ninja 250 Posts: 29	I will try all of the above this weekend --- thankx BTW, I guess I need to post up some pics soon of the Black one in the garage next to the Green slower one and here I am talking bad about green when I have lots of Kawi green shirts plus a 12 ft Green Kawasaki banner in my garage as well as Kawi streamers hanging from the ceiling sorry Greenie owners, my bad LOL __________________________________________________ Jax Kingston TN '04 Kawasaki VN1600 '08 Ninja 250

July 4th, 2013, 01:28 PM	#25
Dark Simple kind of man Name: Ryan Location: Stuttgart, Germany Join Date: Apr 2013 Motorcycle(s): 2013 Ninja 300 Posts: 133	I used a porter cable impact drill and a large Philips bit, both came off in seconds. One can also use a Philips socket on a long ratchet, just keep pressure against the socket and screw. __________________________________________________

July 6th, 2013, 10:07 AM	#37
crazymadbastard I'm crazy,your excuse is? Name: Winston Location: Connecticut Join Date: May 2013 Motorcycle(s): 250 2007 ninja Posts: A lot.	Mine came out after some pounding with a manual impact driver and then used the bit on a ratchet. __________________________________________________ My Cafe Racer Build My intro post

February 20th, 2011, 05:19 PM	#2
bob706 ninjette.org certified postwhore Name: Sean Location: Mary Esther, FL Join Date: Jan 2009 Motorcycle(s): 2008 Ninja 250 1998 HD Road King Posts: A lot.	Heat the screw up with a butane torch for a few minutes then take the impact tool or drill to the screw. Should come right out, just be careful cause it will be friggin hot

February 20th, 2011, 05:21 PM	#3
jax Lifelong Rider Name: Jack Location: East Tennessee Join Date: Apr 2009 Motorcycle(s): mine-> '04 Kawasaki Vulcan 1600,'08 Ninja 250 / hers-> '05 Kawasaki Vulcan 800, '08 Kawasaki Ninja 250 Posts: 29	I'll give that a try thx __________________________________________________ Jax Kingston TN '04 Kawasaki VN1600 '08 Ninja 250

February 20th, 2011, 05:35 PM	#4
kkim Join Date: Nov 2008 Posts: Too much.	http://www.ninjette.org/forums/showthread.php?t=12960 scroll down to post #2.

February 20th, 2011, 06:07 PM	#5
TedBull ninjette.org member Name: Ted Location: NW Wa Join Date: Jan 2011 Motorcycle(s): (08 Ninja 250) (07 Suzuki Hayabusa) (08 Suzuki GSXR 1000) (Yamaha dirtbikes) Posts: 33	I used a cutoff wheel on my angle grinder and cut into the end of the bar end and thru the bolt then the bar ends fell off and I used vice grip pliers to pull out the bolt stud. I did not want to put heat to it and the stock bar ends seemed useless to me so I did not care about damaging them. I ordered new heavy barends and love them. http://www.amazon.com/Kawasaki-Heavy.../dp/B003V12XSW They are inexpensive, great quality, much heavier than stock and beefy. Also I was able to add washers to the inside of the bar end to get the desired space between the bar end and my heated grips.

February 20th, 2011, 07:20 PM	#6
slolane Motorcyclist Name: James Location: Maryland Join Date: May 2010 Motorcycle(s): 2014 Ninja 300 ABS Posts: A lot.	Torch for about 1-2 minutes a side worked for me too and as noted above it will be very hot so be careful. After heating I was able to easily use screwdriver to remove.

February 21st, 2011, 09:44 PM	#7
nexus ninjee two-fiddie Name: Chance Location: Ohio Join Date: Oct 2009 Motorcycle(s): 2008 Ninja 250r Posts: 61	Only heat the screw head, not the entire bar end.Otherwise you might melt your grips. It amazes me that Kawasaki is so liberal on red loctite for the bar end screws, but much more important fasteners on the bike have none.

February 21st, 2011, 10:18 PM	#9
dyeforever ninjette.org member Name: Jesse Location: Kona, Hawaii Join Date: Sep 2010 Motorcycle(s): 04 250r(sold), 09 250r(sold), 07 CRF450x, 07 sv650(sold) Posts: 110	I used a ratchet with a #2 Phillips bit and it came right off.

February 22nd, 2011, 01:09 AM	#11
lunerkid ninjette.org member Name: Ed Location: East Bay Area Join Date: Sep 2009 Motorcycle(s): 08 Ninja 250 Posts: 36	I used a butane torch. As someone said, make sure it is just the bolt otherwise you might start cooking your grips. Afterwards screws come of really easy.

February 22nd, 2011, 05:45 PM	#15
austexjg ninjette.org sage Name: J.G. Location: Austin Join Date: Oct 2009 Motorcycle(s): '09 zx6r Green/Black, (ex-)Diablo Black '09 Ninja 250r Posts: 959	One screw of mine is also stripped - tried to remove before finding the site. Have the screw, but have not had no desire to try to remove the messed up screw after yelling at it back then...

February 22nd, 2011, 08:31 PM	#18
slolane Motorcyclist Name: James Location: Maryland Join Date: May 2010 Motorcycle(s): 2014 Ninja 300 ABS Posts: A lot.	LOL, that's funny! But kkim is right, green is faster!

July 4th, 2013, 12:57 PM	#23
Aggrotech ninjette.org sage Name: Justin Location: Fresno CA Join Date: Jun 2012 Motorcycle(s): 12' Ninja 250 Posts: 831	RISE OLD THREAD! Are there any new methods to removing the bar ends? Dont have an impact gun or heat gun, so i just used a massive bbq lighter and heated the bolt for about 4 minutes, tried, failed..and continued to 10 minutes. could definitely feel the heat when i put my hand on the grip..but to no avail. I know theres a good gallon of red loctite or so on them and ppl seem to get it with a heat gun, but no matter which method or tool i use, it wont budge..not even an inch.

July 4th, 2013, 01:26 PM	#24
bkh2 ninjette.org guru Name: Ben Location: R'lyeh Join Date: May 2011 Motorcycle(s): 2006 GSXR 750; 1983 CB750SC Posts: 277	I used a propane torch (jet lighter would work too). I found that I had to tap the bolt with a hammer several times (and by tap, I mean put some effort into it, but don't go overboard). It should be fairly easy to remove the bolt after that.

July 4th, 2013, 01:42 PM	#26
Aggrotech ninjette.org sage Name: Justin Location: Fresno CA Join Date: Jun 2012 Motorcycle(s): 12' Ninja 250 Posts: 831	Ive tried all the methods in this thread other than the impact gun and obviously drilling the head off. I have a feeling im gonna have to completely destroy them to get them off, just like i did with my oil bolt >_>.

July 4th, 2013, 01:42 PM	#27
choneofakind ninjette.org certified postwhore Name: . Location: . Join Date: Feb 2011 Motorcycle(s): . Posts: Too much. MOTM - Feb '13, Feb '14	Skip all the hassle. 1/4" drill bit and 60 seconds of your time, and that bar end will be off.

July 4th, 2013, 06:01 PM	#29
Aggrotech ninjette.org sage Name: Justin Location: Fresno CA Join Date: Jun 2012 Motorcycle(s): 12' Ninja 250 Posts: 831	i have done it! 16threads of red locktight.... was also heating the bolt throughout the day....that was fckn ridiculous. F u kawi!

July 4th, 2013, 06:06 PM	#31
subxero dirty boy Name: Joe Location: Johnstown, PA Join Date: Sep 2012 Motorcycle(s): I don't even know anymore?? Posts: A lot. MOTM - Apr '14	i got mine out with just a 1/4inch driver and a phillips screw head attachment, sure i broke 2 phillips head bits before i got the one out but they were cheaper bits

July 4th, 2013, 07:00 PM	#34
choneofakind ninjette.org certified postwhore Name: . Location: . Join Date: Feb 2011 Motorcycle(s): . Posts: Too much. MOTM - Feb '13, Feb '14	Yeah they use tons of red locktite there. I drilled the heads on mine, still haven't gotten the shaft of the screws out

July 5th, 2013, 12:56 PM	#36
choneofakind ninjette.org certified postwhore Name: . Location: . Join Date: Feb 2011 Motorcycle(s): . Posts: Too much. MOTM - Feb '13, Feb '14	Yeah well, I don't have the phillips head attachment for a ratchet, but I have a drill and drill bit, so it was cheaper and easier to just drill it since I went with WC bars anyways.

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
Removing the bar ends	ChaoSS	2008 - 2012 Ninja 250R Farkles	2	January 7th, 2013 03:14 PM
bar ends	skikman	1986 - 2007 Ninja 250R Tech Talk	8	January 7th, 2013 06:15 AM
!@#$!ing bar ends! Torch, impact screwdriver, breaker bar, etc ALL failed. :(	CZroe	2008 - 2012 Ninja 250R Tech Talk	64	September 13th, 2012 11:50 AM
ZX-R bar ends	Shaol1n Monk	2008 - 2012 Ninja 250R Farkles	14	July 29th, 2011 12:30 PM
Good kitchen tool for removing bar ends.	irishjohn	2008 - 2012 Ninja 250R Tech Talk	8	August 30th, 2010 07:39 PM