Split bars !

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by rossguzzi, Mar 3, 2013.

  1. rossguzzi

    rossguzzi 990 Adv.

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    Oct 21, 2012
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    I thought my throttle was getting a little hard to turn/return. So I loosened the end bolt that secures the guard and tried to get a little light lube inbetween the bar and the throttle tube. Then I did up the guard bolt. Problem. The throttle stuck. Turns out the bar has a split and when I tighten the bolt in the end of the bar for the guard, it expands the bar inside the throttle tube !!

    Has anyone ever seen this before? I have not.
    I did not over tighten the bolt at all. So some gorilla has worked on this bike at some stage.
    I havnt taken it apart yet. Im hoping I can get a small weld on the outside of the bar along the split and grind back.

    The things you find !!
    #1
  2. buzybraza

    buzybraza Been here awhile

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    Do not fix your handlebar! Replace it!
    #2
  3. KTMbageera

    KTMbageera Adventurer

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    Replace is right. Fatigued bars for whatever reason should not be trusted.

    Treat yourself BIG and put a set of Flexx Enduro hi 15 degree bars. You will never go back.
    #3
  4. jas123

    jas123 Been here awhile

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    What he said, don't do it! Even if you are a competent welder. The type of aluminum usually used should not be welded. You may be able to physically weld it , but the bar strength, will be seriously compromised. Most likely very brittle at and around the weld.
    #4
  5. Kyler

    Kyler Confused Hack Nut

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    get a tap and do the threaded bar end trick. That won't happen again.
    #5
  6. rossguzzi

    rossguzzi 990 Adv.

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    Not sure what this bar end trick is?
    #6
  7. Kyler

    Kyler Confused Hack Nut

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    51st State - Western MD
    #7
  8. charlie264

    charlie264 Long timer

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    I replaced my standard bars for RC High Fat Bars on my KTM 950 SE. I also fitted heated grips and Acerbis RALLY PRO X-STRONG hand guards….I notice yesterday that the left hand guard was loose…
    The reason the hand guard was loose is because the Fat Bar has split in two under the grip.
    #8
  9. desert sky

    desert sky Adventurer

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    #9
  10. Peanuts

    Peanuts Long timer

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    I wonder how easy it is to drill and tap a grubscrew like thay have done? Thought it would be quite hard steel.......
    #10
  11. charlie264

    charlie264 Long timer

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    You can buy um....Ive got some for wood but they are to big and the thread is like a wood screw. I'm going to try fasteners shop tomorrow.
    #11
  12. Peanuts

    Peanuts Long timer

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    I have ground the corners off an M8 long nut in the past, then bashed it into the bar with a smear of bearing retainer.

    [​IMG]
    #12
  13. charlie264

    charlie264 Long timer

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    I thought of using a die on one....then tapping the bar.
    #13