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How to remove bar ends?

17K views 11 replies 10 participants last post by  Chewy  
#1 ·
So I am looking to make the handle bars width more narrow, for easier lane splitting and just personal preference. I was thinking of taking a dremel to the ends of the bars and just sawing off an inch or two. The issue is I do not know how to remove the internal bar end. I see a lot of other bikes generally have a clip that you pull and that releases the tension on the bar end, but I do not see any clip for the xsr900 bar end. Any ideas how to remove it? Thanks.
 
#3 ·
You do know that the bars are drilled for the locating pegs on the switches? So you will either have to dremel off the pegs on the switch units, and use double sided tape to stop them from slipping, or you will be limited to cutting down the grips (and throttle tube) to reduce width. (You will also need new bar ends that have an expanding sleeve as you will have sawed off the section of bar that has the threads in)
 
#4 ·
Another option -

Why not do a little research on a new handlebar with the dimensions you want. That is much better than sawing your stock bars. Because if you mess up in the least or if you do not like it, you cant ride till you get another one. Gotta think things through man.

Plus if you don't like the new one - you can just swap back to the stock one and get a refund.

No hassle, no cutting, no bloody knuckles, no swearing....its a win win
 
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#6 ·
Another option with new handlebars is to not completely cut off the index pins on the controls. You can cut them down just enough so they grip onto the new bars to hold them in place.



You can also use a little Clear RTV Silicone Adhesive to hold them in place. Once the silicone sets, they are not going anywhere, but it can still be easily removed if needed.
 
#8 ·
I have already dremeled off the dimples on the throttle and clutch housing without any issues. It'd be easy enough to move the levers in an inch, without any issues with the cables. Getting another handlebar would still require me modifying it to the exact dimensions that I'm looking for and require me to buy new bar end inserts anyways. So I guess you can't take out the inner core of the bar end? The handlebar itself is threaded to accept the bar ends?
 
#11 ·
I bought the Woodcraft adapters with a 1" drop. The new bars are definitely much lower and more narrow than the stock bar. Even with a bar end mirror on the left side, splitting is a breeze.

For the price, I wouldn't do it any other way. I can always just swap my stock back back on if I ever need to go back to stock.