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Discussion Starter #1
I know there are several posts on those pesky bar weights, but I have a plan and wanted to get some feedback before I proceed.

I am installing Barkbusters, so I don't need the parts from the OEM weights but would like to keep them around in case I want to go back to stock. The right side assembly came out no problem (it was loose to start with).

The left side just won't budge. I can loosen the screw as much as I dare and I know the end nut if freely moving in and out with the screw. It appears to be the first rubber expander part which is wedged up.

I have tried spraying some WD40 in there as I work the weight up and down and around and keep pulling.

Since I can sacrifice the parts, I was thinking about backing the screw out all the way, pull out the screw and the spacer tube and then roto-rooter the rubber part (dremel, drill bits, sharp metal hook like thingy. If I can clear that part out (and the washer embedded in it, then the end nut should be up the tube. I can either leave it there or blow it out with compressed as other have posted.

Anybody see a problem with this plan, or has some other things to try to get that rubber part out? I suspect the washer in it was has wedged itself up compressing the rubber so much it is pretty much bonded. It probably hasn't been touched since the bike left the dealer in 02.

Thanks for any ideas.
 

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I know there are several posts on those pesky bar weights, but I have a plan and wanted to get some feedback before I proceed.

I am installing Barkbusters, so I don't need the parts from the OEM weights but would like to keep them around in case I want to go back to stock. The right side assembly came out no problem (it was loose to start with).

The left side just won't budge. I can loosen the screw as much as I dare and I know the end nut if freely moving in and out with the screw. It appears to be the first rubber expander part which is wedged up.

I have tried spraying some WD40 in there as I work the weight up and down and around and keep pulling.

Since I can sacrifice the parts, I was thinking about backing the screw out all the way, pull out the screw and the spacer tube and then roto-rooter the rubber part (dremel, drill bits, sharp metal hook like thingy. If I can clear that part out (and the washer embedded in it, then the end nut should be up the tube. I can either leave it there or blow it out with compressed as other have posted.

Anybody see a problem with this plan, or has some other things to try to get that rubber part out? I suspect the washer in it was has wedged itself up compressing the rubber so much it is pretty much bonded. It probably hasn't been touched since the bike left the dealer in 02.

Thanks for any ideas.

Tap on the screw to nock the nut out of the expander sleeve.
 

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What he said. Take everything out that will come out, thread the screw back into the nut and give it a little tap. The nut has probably mashed itself to the rubber grommet and this is preventing it from un-expanding as thus allowing it to come out.. You may have to devise a plan to construct a slide hammer to get the grommet out.
 

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Former bicycle shop mech take off the cap and put the screw back in at least 4or 5 turns. To have a good bite spray some wd40 through the screw hole first to get some lube behind the rubber tap maybe kinda hard to loosen the nut from the rubber then tap the rubber wedge in just a bit to make it move then try to remove the wedge with the screw maybe some needle nose for leverage
 

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Discussion Starter #6
Thanks all. One of the reasons I got a Strom, because of the troopers. :thumbup:

To be clear the end nut is moving fine, I can tell because the screw is still engaged with it and I can slide it in and out. It is the first expander grommet that is wedged.

But I concur, I should be able to take the screw and as much of it out as possible, and then should be able to get to that wedged expander and work on it directly. Then if it loosens up, hopefully I can rethread the screw into it without pushing it further back into the bar and draw the wedge grommet and end nut (and its rubber) out together.

Like I said, it I can't reengage the end nut.....no biggie, I'll use air or a snake to push it out from the other side. If I got to tear up the first rubber part....again, no issue, barkbusters replaces all of that with a solid metal system.

Will try all the ideas and let you know what I came up with.
 

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I've lubed one up with silicone or WD40 then used the nail puller end of a wonder bar over the screw shaft and wacked with a hammer to pop out the wedge . Keep the nail puller end perpendicular to the screw shaft. Works sort of like a slide hammer.
 

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You have to hold the bar end weight so it does not turn.
 

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Discussion Starter #9
Madstrom,

Thanks. I tried some 'impact' actions by getting an open ended wrench between the bar end weight and the end of the handlebar (I can get it out by about 3/8" just by loosening the screw and a little slip in the system). I hit the wrench with a hammer with no luck, and didn't want to break my wrench (yes, craftsman do break too).

But pulling on the screw is another option, my only concern there is that the screw is fairly soft, if it snaps, I got a much bigger issue and a blocked tube that I can just push all the stuff further back into.

I think the stuck rubber is going to be sacrificed and reamed/cut/drilled out, unless I can use a small screwdriver to loosen it up first and then pull it out.
 

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In addition to the above, squirt or pour some rubbing alcohol in handlebar. This works on grips and any other rubber parts that stick. Used it for years.Thats the ONLY way I got mine out. They are a pain! Using alcohol you should not have to sacrifice the rubber!
 

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Discussion Starter #11
Success! Got it out

All. Thanks for the inputs. I tried some more yanking and pulling today with no success, so I back out the screw some more, still didn't help but I could see further into the bar. Eventually I backed out the screw completely and drew out the spacer sleeve.

I used a screwdriver and the expansion plug moved fine with no resistance so I hooked it and pulled it out, then put the screw back in and rethreaded the end nut and its rubber sleeve and pulled it out no issue.

What I found is that the expansion plug did not look like a standard part...the whole assembly on the left looks different then the right side, and there were some extra washers thrown in there........my best guess.....somebody lost some parts and kluged up a system that sort of worked but not really.:yikes:

The correct assembly is designed so unless you draw the end screw up the expansion grommet doesn't expand allowing to slide the assembly in and out without expanding the plug. The kluge job was a one way setup, it expanded as the end nut pushed against it when I tried to withdrawn the assembly out.....the OEM assembly won't do that, only if you turn the screw and shorten the effective length of the assembly.

Once I got all the parts out and pulled the plug out (rather than pushed it) it slid fine.

Anyway, its all out, I will not use those parts again to not screw the next owner of the bike. The barkbusters went on fine after that :thumbup:

Thanks again for ideas.
 

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Sorry to hijack the thread, but I installed the barkbusters today, there's not a chance I could have removed the old bar weights without reading these threads. I would have pulled that end screw all the way out without knowing all the crap that lives inside the bars, thanks to your pics and info on removing them.

thanks
frank
 

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Discussion Starter #13
yep, that's why I research everything, tons of knowledge and experience.

I am thinking about using some non-seize on the parts going back in. I know they are all metal, and a mix of aluminum and steel and not too intense pressures, but I figure expanding that metal plug, driving the wedge nut into the expander, etc. and then letting it sit in there for years....I don't want any issues down the road. You got to be able to take those things off for various maintenance jobs on the bars. I would rather have to tighten them up occasionally then have to drill out metal next time.

But the Barkbusters went on nice, super quality components, very happy.:thumbup:
 
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