help! problem with handlebar replacement

[cummuterguy]

I went out today to put my new handlebar on the bike, but i have a prob. the new handlebar doesn't have any threads to screw the bar-end into it. I looked in the old bar to see if i can get the old one out, but I cant see anyway to get it out of there. The left side came with a new bar end and the rubber grommet/nut assembly to hold it in place.no problem there, but the right side didn't come with anything, and i cant get the old stuff out to re-use my old bar-end so I'm stuck... any clues?

[Michael]

Have you tried putting the bolt back into the right side and using that for the leverage needed to get the bit out?

[cummuterguy]

i tried that briefly, but decided i'd rather see if anyone had a trick to it, before using too much force and breaking my bolt

[Kerry]

I'm pretty sure the threaded inserts are welded in place.

Juat about your only option is to get another compression-fit bar end for the right side.

[cummuterguy]

crap....  oh well, kinda what I was afraid of...

[JetSwing]

I'm pretty sure the threaded inserts are welded in place.

huh? welded to the bar? not true...

cummuterguy, i've assembled the barend before i sent it to you (nut-ruuber-nut-barend). all to have to do is slide the assembly in the bar. tighten the bolt (screw) enough to so that two nuts compresses the rubber piece (which holds the barend in place). this part is kind of tricky....let me know if you have problems.

to get barend assembly out of the handlebar, use a screw driver. stick it in the core of the rubber piece and wiggle it out. this take some patience. nuts are loose and should slide out.

[cummuterguy]

JetSwing, no problems with the one that you sent, my problems are with trying to use my old one for the other side. there's nothong to attach it to in the new bar, and I can't get the "nut" out of the old bar.

[cummuterguy]

i think Kerry is right, cause I can see some spot welds on the old bar that arent on the new one, must be a difference between the 2000 and 2001 model years

[starwalt]

It seems we may have more than one type of handlebar out there. The bar off my ebay bike has welded threaded inserts.



This is interesting. I know my project bike has been abused but is the bar that came with it the original? It is bent. I bought Kee's handlebar and will be getting it next week. Photos to come after receipt. (Yes, Kee. The world will know.  :mrgreen: )

[JetSwing]

hmmm...does it (your old barend) have a rubber part? welding a bolt inside the semms very old school...

i can send you the other barend but like i've told you before, it's missing the rubber part...it's useless without it.

[JetSwing]

i've compared 2000 and 01 fiche...and they're different!  :dunno:

if you have a rubber part, i can send you the other barend!

[starwalt]

It can not be seen in the second pic but, a bolt is broken off in it. There is no rubber in either bar end. IF this bar is original, it would be from 1989. The bike has  07/89 on the VIN tag. The junk GS did not have handle bars. I do not know the date of Kee's soon-to-be-mine handlebar but will check it out and post back here.

[Kerry]

IF this bar is original, it would be from 1989.

If this were an original '89 bar, it wouldn't BE a bar.  It would be clip-ons instead.

The bike has  07/89 on the VIN tag.

And my '99 has 4/98 on the VIN tag:



The surefire way to tell the model year is to check the second stamped letter.  See this post or Chapter 0 in your Haynes manual.

[cummuterguy]

Starwalt's picture shows what my old bars had on them, exactly!

apparently there are two different methods of attaching. I wonder if it's a model year thing, or maybe different factories used different methods?

So anyway, JetSwing, if you don't mind, send the other barend, i'll just fabricate a bushing from an old shock bushing or something. I have plenty of stuff like that lying around. then i will have both barends looking the same (there's a slight diemeter difference as well, my old one is just a bit narrower)
Sent a pm to you also regarding this. Lemme know how much you need for the part and shipping.

[Kerry]

I wonder if it's a model year thing, or maybe different factories used different methods?

As far as I know, the '90-'00 model years all had the welded-in threaded inserts, and the '01+ models have the press fit bar ends.  Just another of the many small changes that were made in '01.

[starwalt]

Just to sync up, my ebay bike and the junk donor are both "L" models. That would make them 1990 year models.

I refer to them as 07/89 and 10/89 sometimes. Lately they are  "ebay bike" and the "junk donor."

BTW the donor has a bent left tube. That makes sense because of the bumper or curb sized depression in the left side of the front wheel. It was a shame to pitch an entire bike because of that. I suspect it was a tradein for another ride considering the shop where it was found.