Removing the bar ends

ChaoSS · January 7th, 2013, 02:41 PM

Ok, so awhile back I laid the bike down, and it damaged the bar ends, specifically, it chewed up the screw head that holds on the bar ends.

Fast forward to two weeks ago, I went to install heated grips on the bike, got the left side off ok, but trying to get the right side off it just stripped the head out. So I went down and bought some screw extractors from sears, and that is the last time I ever buy anything from craftsman. I'm done with their made in china garbage.

I broke two drill bits from the set, couldn't even try to get the extractors themselves in, and the second bit that broke off, ended up slamming into the fairings and did some damage there that won't just buff out.

So now I'm thinking it's time to just buy a new bar end and cut this one off. I figure if I cut it at the right depth, it should cut off the head of the screw, the bar end should come off, and there should be enough screw sticking out that I can get some locking pliers on it and muscle it out. I really don't want to screw up my handlebar though, I can't afford to replace it right now, I really don't want to replace my bar end.

Does anyone have any ideas? Is there anything different about this side that will cause me to damage something or make it not work? It would work on the other side, but this side has the throttle, so I don't know what's different under there.

lgk · January 7th, 2013, 03:07 PM

You probably should have torched the bar end before applying the easy out, the small ones usually aren't made for loctite removal.

If the screw is not bent from the crash you can drill out the head and try vise grips.

Otherwise, i would go to sears to exchange the bits, then a propane torch and small tank and try again.

ChaoSS · January 7th, 2013, 03:14 PM

Never mind I got it.

I was going to try to use the biggest bit to drill out just the head, it was about the right size, but it dulled out before going in far enough.... (what is that, a quarter inch? F*** Craftsman junk)

Anyway, there was that little hole, so I put a vise grip on the bar end, twisted it a little, which broke loose the screw just a little bit, and I stuck the easy out in there and tried to turn it out. It just spun in there, so I stuck the easy out in the vise grips and put sideways pressure on it, it was just enough to get it to bit enough to turn it out.

Now I get to put that heated grip on, I'm tired of having one hand frozen stiff on my way home.

January 7th, 2013, 02:41 PM	#1
ChaoSS ninjette.org sage Name: Tim Location: Goshen CA Join Date: Oct 2012 Motorcycle(s): 2012 red 250 ninja Posts: 740	Removing the bar ends Ok, so awhile back I laid the bike down, and it damaged the bar ends, specifically, it chewed up the screw head that holds on the bar ends. Fast forward to two weeks ago, I went to install heated grips on the bike, got the left side off ok, but trying to get the right side off it just stripped the head out. So I went down and bought some screw extractors from sears, and that is the last time I ever buy anything from craftsman. I'm done with their made in china garbage. I broke two drill bits from the set, couldn't even try to get the extractors themselves in, and the second bit that broke off, ended up slamming into the fairings and did some damage there that won't just buff out. So now I'm thinking it's time to just buy a new bar end and cut this one off. I figure if I cut it at the right depth, it should cut off the head of the screw, the bar end should come off, and there should be enough screw sticking out that I can get some locking pliers on it and muscle it out. I really don't want to screw up my handlebar though, I can't afford to replace it right now, I really don't want to replace my bar end. Does anyone have any ideas? Is there anything different about this side that will cause me to damage something or make it not work? It would work on the other side, but this side has the throttle, so I don't know what's different under there.

January 7th, 2013, 03:07 PM	#2
lgk ninjette.org certified postwhore Name: Jason Location: Norfolk, VA Join Date: Dec 2011 Motorcycle(s): 2012 EX250, 2014 EX300 Posts: A lot.	You probably should have torched the bar end before applying the easy out, the small ones usually aren't made for loctite removal. If the screw is not bent from the crash you can drill out the head and try vise grips. Otherwise, i would go to sears to exchange the bits, then a propane torch and small tank and try again. __________________________________________________ Ethioknight Memorial Fund- Sticker sale http://www.ninjette.org/forums/showthread.php?t=111700

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January 7th, 2013, 03:14 PM	#3
ChaoSS ninjette.org sage Name: Tim Location: Goshen CA Join Date: Oct 2012 Motorcycle(s): 2012 red 250 ninja Posts: 740	Never mind I got it. I was going to try to use the biggest bit to drill out just the head, it was about the right size, but it dulled out before going in far enough.... (what is that, a quarter inch? F*** Craftsman junk) Anyway, there was that little hole, so I put a vise grip on the bar end, twisted it a little, which broke loose the screw just a little bit, and I stuck the easy out in there and tried to turn it out. It just spun in there, so I stuck the easy out in the vise grips and put sideways pressure on it, it was just enough to get it to bit enough to turn it out. Now I get to put that heated grip on, I'm tired of having one hand frozen stiff on my way home.