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Discussion Starter #1
Bike fell over and bent the right hand bolt that holds the bar end weight. I removed the bolt to straighten it. Now I cant get the bolt to thread into the threaded insert inside the right handgrip. How does one go about this?

Thanks!
 

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uhhh...remove the left one also. The insert may be tweaked now
 

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Discussion Starter #3
The threads on the bolt are fine I tested them with a nut the same size. I cant even see the insert anymore inside the handlebar. I tried leaning the bike to the right as far as possible and smacking the handlebar with a mallet. I tried removing the throttle. WTF?!
 

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FORUM GODFATHER.....R.I.P. PAT
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The threads on the bolt are fine I tested them with a nut the same size. I cant even see the insert anymore inside the handlebar. I tried leaning the bike to the right as far as possible and smacking the handlebar with a mallet. I tried removing the throttle. WTF?!
You need to fish it out or blow it out with air from the other side. Many of us have made this mistake of separating the two pieces when taking them out. You only need to unscrew the end enough to be able to pull the insert out. My insert was so far back that I finally took the left side off and used compressed air to blow it out.
 

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Discussion Starter #6
I get it. Dont have CA and an electrical cord with the plug cut off wouldnt push it out. Dont have a snake. Good idea though!

It is hot out and I am very cranky right about now.

I will be a polite as possible here.


Suzuki should have made the threads of the bolt so the square nut could not back off them. What were they thinking?
 

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FORUM GODFATHER.....R.I.P. PAT
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They were thinking people would read the manual.

NOTE:
Do not remove the handlebar balancer mounting screw before
removing the handlebar balancer. Slightly loosen the mounting
screw, and then pull the balancer assembly out of handlebars.
 

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Discussion Starter #8
Oh they really are MORONS then. They knew this could happen and built it like that anyway. It would have been so simple to make that bolt so the nut could not fall off. Which is better: burying a warning on page 285 of a manual. Or making sure it cant happen in the first place? Which wouldnt have cost them a cent.
 

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Solution!

Hi,

I solved this problem really quickly, so I thought even though this thread is over 2 years old, I'd post the solution here. My bike was blown over last night because I stupidly didn't tie down the cover, and in the high winds in the Bay Area last night it acted like a parachute and pulled my baby over to the right. Bent bar-end bolt like the original poster had. And yeah I stupidly just pulled the screw out and didn't read the manual, and lost the nut inside the bars.

Thank god for this forum and for the last guy who posted the motorcycle parts website, which had a blow-up diagram of how the whole assembly hangs together. I simply cut up a wire coathanger into a 6-inch section with a 5mm (about 1/4") hook bent into the end of it, and at the other end, a decent sized curl so I could hold and manipulate my makeshift hook tool. Stuck it down the handlebars, through the expander's hole, then used the hook to pull out the expander. It was tricky but I was able to stick a pinky in there to hold the wire hanger/hook in place. After that, I was able to use the same tool to hook the loose nut and drag it out of the bars. All without any need to tilt the bike or use compressed air. Is there any way for me to post a URL here so I can show you a photo?

Ok, here's a photo, hopefully it uploads OK. I put a quarter next to it for scale. The curl in the 'handle' end was already part of the coathanger - I'm not *that* good with pliers!

 

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That's usin' yur noggin! Nice work at re-purposing the "multi-tool" coat hanger too!
 

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Even though the thread is a bit old for us newbies that is a good explanation and tip- now that I 've seen the expanded view ( thanks to link by Graywolf) it seems my next wrenching episode will involve a coat hanger. Your pic was not up but the hook can only be so big to fit through the expander hole anyway.
 

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blow it out with air from the other side.

Yup, this is what did the trick. Was putting grip puppies on my brothers bike today, and ran into this problem, and air made it easy.
Thanks for the tip
 
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