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Old December 20th, 2012, 07:47 PM   #1
ShadowStalk3r
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Ninja 250R bar end bolt.

Well I've just replaced the left handlebar on my bike recently but I've been struggling to put on the bolt that go on at the end of the bar. The problem is that it require so much force to turn the bolt that I end up bending the bolt instead. Is there some special tool I suppose to use for this? I thought it was just a simple screw on with a wrench.
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Old December 20th, 2012, 08:12 PM   #2
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The trick is heat. It's on with loctite, so brute force alone isn't always successful. A small pencil torch to warm up the bolt quite hot, then allows it to come right out without stripping.
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Old December 20th, 2012, 08:32 PM   #3
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The trick is heat. It's on with loctite, so brute force alone isn't always successful. A small pencil torch to warm up the bolt quite hot, then allows it to come right out without stripping.
No the problem I'm having is putting it back on. I know most people struggle to take it off, but it was easy to take off for me. Some reason I can't put it back on.
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Old December 20th, 2012, 08:42 PM   #4
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Ah! reading fail. Are you sure it's the right size/pitch bolt?
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Old December 20th, 2012, 08:49 PM   #5
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Ah! reading fail. Are you sure it's the right size/pitch bolt?
Yeah I thought about that as well, so I went back and tried putting the original bolt on the old handle bar and it only turn a few times before it become stuck. I have no idea wth is going onIt was so easy to take out...
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Old December 20th, 2012, 09:27 PM   #6
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Originally Posted by ShadowStalk3r View Post
Yeah I thought about that as well, so I went back and tried putting the original bolt on the old handle bar and it only turn a few times before it become stuck. I have no idea wth is going onIt was so easy to take out...
OK so there is just to much lock-tight in the threads or you have damaged the threads getting the original bolt out.

What you need to do is clean and or re-tap the threads with the proper sized tap. 8mm-1.25mm, please can someone confirm the size or I'll double check tomorrow. Just clean out the threads with the tap apply new lock-tight green or blue please not red, and screw it back on.

hope this helps
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Old December 20th, 2012, 09:33 PM   #7
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OK so I just got off my lazy ass and walked the 20' to my garage and it's confirmed bar end bolt and tap size is 8-1.25mm
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