Help! Missing part for handlebar end caps?
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Junior Member
Squid
Joined: Oct 2015
Posts: 11
Help! Missing part for handlebar end caps?
I am having trouble installing new handlebar end caps that I purchased after losing the throttle side one on the ride home from the dealership last fall. The left side end cap threads in correctly, but my throttle side one does not. The threads are too small only on the throttle side. Did a part fall off when I lost the other end cap?
Senior Member
Superstock
Joined: Nov 2014
Posts: 416
From: Middletown, CT
Looks like they aren't "too small" i.e. smaller diameter, but they may be shallower in depth. Most aftermarket bar end weights come with an expanding rubber tube meant to grab the inside of a totally hollow race style clip-ons. OEM clip-ons have a steel weight glued inside the tube that is threaded internally and also keyed to prevent rotation. So if your new ends came with the rubber tubes you need shorter allen capscrews... Yes? Cool?
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Junior Member
Squid
Joined: Oct 2015
Posts: 11
Thanks for the quick reply Fastguy. Sorry for the confusion but the first picture is to demonstrate the bolt on the left side of the handlebar (clutch side) is the correct diameter and just not screwed in all the way. The second picture is of the right side of the handlebar (throttle side) where the bolt is actually smaller in diameter than the threads inside the bar. Which is why it leads me to believe I must be missing something that threads into the bar as well so it is the smaller diameter like the left side of the handlebar.
Senior Member
Superstock
Joined: Nov 2014
Posts: 416
From: Middletown, CT
SH handlebar fiche
As you can see in the fiche (1999 SH) both bar ends weights, screws, rubber expanders, and rings are of the same diameter... so I'm thinking that maybe the one that looks smaller is because the ring and rubber maintained a compressed profile therefore the hole in the middle looks smaller
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Squid
Joined: Oct 2015
Posts: 11
I have a 2003.
The only issue is that the hole is larger than the bolt that came with the bar end cap, by like an entire size up. I will take some more photos of the handlebar ends tonight so you can really see the issue.
As you can see in the fiche (1999 SH) both bar ends weights, screws, rubber expanders, and rings are of the same diameter... so I'm thinking that maybe the one that looks smaller is because the ring and rubber maintained a compressed profile therefore the hole in the middle looks smaller
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Squid
Joined: Oct 2015
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Thread Killer
SuperBike
Joined: Apr 2013
Posts: 2,093
From: Geneseo, IL
The stock parts in the clip on are the same on both sides as Fast guy points out, so I suspect you have aftermarket guts on the right. It seems you could just get a proper sized bolt for the right and carry on. Beyond that, you'd probably have to get the guts out of the right side to see what you're working with in order to determine if you want to replace any missing stock parts (if available) or what.
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Junior Member
Squid
Joined: Oct 2015
Posts: 11
Really appreciate the help so far. I cannot simply use a larger bolt that will work with the threads on the right side. The larger bolt will not fit through the hole in the bar end cap that I purchased. Very confusing that there would be a smaller threaded hole on one side versus the other.
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Junior Member
Squid
Joined: Oct 2015
Posts: 11
FYI, I also tried to get the guts out of the left side bar as I think there is a weight that is threaded into that side with the smaller internal threads. Problem is I could not get the guts to come out.
That one guy
Back Marker
Joined: Jun 2015
Posts: 228
From: Broken Arrow
But if it is seated that well in there the better option would be to use a keen insert into the bar end that matches what's in the slip on. You will probably have to drill and tap the bar end to accept the keen insert but the problem will be resolved.
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