Barkbuster Removal Help Needed - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 14 Old 01-19-2015, 10:57 PM Thread Starter
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Barkbuster Removal Help Needed

I just bought a used 13 glee with Barkbusters already installed. I wanted to install Grip Puppies over the factory grips so I removed the end bolt from the Barkbuster on the throttle side. Of course when I tried to reinstall the Barkbuster bolt I realized the spacer and nut inside of the handlebar did not grip the bolt. I tried in vain to remove the aluminum washer/insert which is inside of the bar end so that I could re seat everything. No luck. Now I realize I should have wiggled the expander out of the inside of the bar to avoid this problem. Any suggestions on how to fix this would be great.
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post #2 of 14 Old 01-20-2015, 02:21 AM
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longer bolt

Try a longer bolt and tip the bars so that gravity pulls the spacer towards the outer section of the tube and see if you can re thread the expander and pull it out

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post #3 of 14 Old 01-20-2015, 03:57 AM
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I had to take the bars off so I could tip them enough to shake the nut out.


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post #4 of 14 Old 01-20-2015, 09:03 AM Thread Starter
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Thanks for the replies, but I'm afraid that I've already used a screwdriver to push the nut through- past the expander. So I need to get the expander out of the bar so that I can recover the nut. The pisser is that I called TT for help and they'd never heard of this problem and suggested the screwdriver. Ugh...
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post #5 of 14 Old 01-20-2015, 09:11 AM
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Take the other side off not duplicating your current problem, and use a length of flexible hose to push the bits back out. A magnetic pick up tool will help.

Reading this again, is the expander wedged in the bar still, or just loose and fallen down the bar?

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Last edited by ARATA; 01-20-2015 at 09:14 AM.
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post #6 of 14 Old 01-20-2015, 09:27 AM
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I had a similar problem when I was installing mine. I called TT and they suggested a pick. It was tight, but I was able to make it work.

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post #7 of 14 Old 01-20-2015, 11:11 AM
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Take the other side off and run a wire throughout the bar.
Push the wire through the bad sire first until it goes through the whole bar.
Then attach something to the wire and pull it back through dragging out the expander.

It's a good idea to spray some lubricant through the bar to make it easier to drag out the expander.

Now for the more important part.

Order new bolts, expanders and the little expander nut.

Because these get tightened a lot when installed you do not want to use them twice.

Also use a good socket wrench alan key when installing And shove a wee pit of paper into the bolts alan wrench hexagonal hole so the tool fits really snug.

So as to make it easier to remove the whole lot again in the future put in some blue locktite
on your mounting hardware so it does not oxidize.
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post #8 of 14 Old 01-20-2015, 11:56 AM Thread Starter
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All great ideas and I will heed the advice. My current problem is the expander is wedged inside the bar. It hasn't pushed in any further and is even with the end of the bar. I'm not sure the pick method would be strong enough for my problem. Once I get the expander our I can start the nut rescue. I'm going to go work it some more. I will order the new expander and bolt parts also.
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post #9 of 14 Old 01-20-2015, 12:09 PM
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Yea, my expander was stuck too, the pick worked for me. I marred the expander a bit, but it has held well for the last 6K miles.
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post #10 of 14 Old 01-20-2015, 01:44 PM Thread Starter
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Thanks. I'm going to buy some picks.
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