Broken Bolt In Handlebar Weight

Uncle Phil

Uncle Phil

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Joined
Feb 26, 2007
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11,165
Age
72
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In The Holler West Of Nashville, Tennessee
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4 ST1100(s)
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Any ideas on getting a sheared handlebar weight bolt extracted from the handlebars?
I don't use 'easeouts' as I have never had one that didn't end up breaking and then you have this ultra hard 'easeout' you have to drill out on top of drilling the bolt. ;)
No portion of the bolt is extending out so I can't weld to it or grab it with a pair of pliers.
I'm thinking a left handed drill bit at this point.
 
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To prevent excessive stress on oneself, I would suggest getting another pair of bars......

I have other suggestions but they mostly involve doing violence to the current bars having removed them from the bike....
 
Firstpeke said:
To prevent excessive stress on oneself, I would suggest getting another pair of bars......

I have other suggestions but they mostly involve doing violence to the current bars having removed them from the bike....
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These already have the heated grips, etc. that I use so if I can just get that bolt out I would be good to go. ;)
I wonder if it is possible to remove the bolt 'receiver' out of the handlebars to work on it then reinstall it where it works as it should.
 
If it is like an ST1300 can't you remove the bar weight 7 from inside the bar after removing clip 9? On the 1300 you have a hole in bar to push the clip in and release.

Then if you can't get the bolt out buy a new bar weight.

11barend.jpg
 
WØQNX said:
If it is like an ST1300 can't you remove the bar weight 7 from inside the bar after removing clip 9? On the 1300 you have a hole in bar to push the clip in and release.

Then if you can't get the bolt out buy a new bar weight.

11barend.jpg
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Nope, the ST1100 has an 'insert' into the hollow end of the handlebars that the bar weight bolt screws into.
 
WØQNX said:
that is an 1100 parts fische photo.

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Well duh - somedays I'm a little slow and some days I'm a lot slow. ;)
I'll take a look at that then.
**EDIT - Just looked at it and it does not 'look' like the fische.
The ones I have are ones with a solid metal insert into the end of the handlebar with two raised lips to keep the weight from turning when tightened down.
And #8 which is called the 'handlebar weight' is not what it looks like to me as I thought the 'barweight' was the big black weight screwed into the end.
 
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Trvmtchll said:
Drill it out and tap it to a bigger size would be my next suggestion if your not a fan of eazyouts..
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If it is like the 1300 the bar weight it will spin in the bar if you try to drill and tap it while in the bar.

Can you grab the bar end and turn in while in place like on a 1300? That's what it should do with the rubber spacers inside around the bar weight. It is for weight and isolation of vibrations via the rubber spacers.

And for your next question. "If I push the clip 9 in how do I pull the bar weight out?"

Remove the grip and push the clip in on the good side and use the unbroken bolt to pull the other side bar weight out. Assuming they are one long bent tube for a bar, drop 40 ball bearings in the bar and use them to drive the side with no bolt out. Understand? Or maybe air pressure applied from the good side end.

But since I are a former machinist guy, first I'd carefully drill a small dimple off center in the broken bolt end and try to spin the borken bolt out with a small point punch (or a tap with a point on the end used as a small pointed punch). If that doesn't work drill another very small dimple on the other side of small broken bolt and try a small screwdriver. That bolt shouldn't be too tight since it was broke off when the bar end "hit".
 
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If it is the right hand bar end it takes a hammer and swearing at it. If it the left hand one all you need to do is make it want to come out on its own
 
My next suggestion was to do the drilling out thing and retap...... or put a long flexible rod in from the other end that would allow some tapping physically with a tapometer...... of course the long flexible rod is not feasible given the bends of the bars...

I guess one really needs to be there to properly understand the requirement!!!

The previous post from WOQNX may prove good to go.....
 
This is the picture of the ST1300 internal bar weight. Your bar end mates to that half cut across the bar end.

1300bar.jpg
 
UP, am I being a little slow, I take it the end weight is off and the screw has snapped off.
That should mean everything inside SHOULD be relaxed. Can you grab hold of the gubbins with some'at and pull it out?
If it's still tight punch the screw in and see if that loosens it up.
Upt. And definitely snail like.
 
Upt' North said:
UP, am I being a little slow, I take it the end weight is off and the screw has snapped off.
That should mean everything inside SHOULD be relaxed. Can you grab hold of the gubbins with some'at and pull it out?
Upt. And definitely snail like.
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It won't come out until clip 9 is pushed inwards. That keeps the entire assy. inside the bars not the bolt. Clip 9 drops down into a hole drilled into the handelbar.

click on the link to part 9 in the fische link. The clip goes both in the bar and the weight via the bent over ears.
 
Upt' North said:
UP, am I being a little slow, I take it the end weight is off and the screw has snapped off.
That should mean everything inside SHOULD be relaxed. Can you grab hold of the gubbins with some'at and pull it out?
If it's still tight punch the screw in and see if that loosens it up.
Upt. And definitely snail like.
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The problem is the 'business' end of the bolt is still in the handlebar keeping everything 'tight'.
 
WØQNX said:
It won't come out until clip 9 is pushing inwards. That keeps the entire assy. inside the bars not the bolt. Clip 9 drops down into a hole drilled into the handelbar.
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Raymond - I can't seem to get an understanding of exactly where #9 is located - the fiche seems to indicate on the outside.
And there's no picture of the 'external' weight there.
What am I missing?
Here's some pictures -

Good Right Grip -
Good Right Grip.jpg

Bad Right Grip -
Bad Right Grip.jpg
 
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If you remove the grip first then you can press in the ears of clip 9. Both these guys did it wrong.


 
Does removing the grip allow access to the clip?
I don't remember a hole in the handlebar that would allow access - but then I've been wrong before. ;)
And now I know what I thought was bar weight are actually bar ends!
If I have to remove the grips (this is the throttle side) I might as well replace the handlebars since I have a few 'sets'. ;)
 
Yes the hole is under the grip. Throttle side is baaad. I hope you can get the bolt out.

I only know ST1300 but here is the hole on some ebay parts.

s-l1600.jpg
 
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