Handlebar end bolt

[AlanB]

Recently I lost one of the handlebar end bolts off my 1200GS. I went to Oxford BMW for a replacement (the guy I spoke to in the Service dept actually had one in his hand at the time, and he gave it to me, on the house. Nice one.)

Anyway, when it came to refitting, I've been having difficulty getting it in past the first 10 turns or so. It's still about half an inch short of seating. All I can think of is that the original was held in with some kind of locking compound, and that there is some residue inside the bar, which is obstructing the new bolt. Would this be a fair assumption, and if so, is there any easy way of clearing it out, or do i just continue working the new one in a bit at a time?

Alan

 

[Roadsweeper]

Can't get it all the way in

Recently I lost one of the handlebar end bolts off my 1200GS. I went to Oxford BMW for a replacement (the guy I spoke to in the Service dept actually had one in his hand at the time, and he gave it to me, on the house. Nice one.)

Anyway, when it came to refitting, I've been having difficulty getting it in past the first 10 turns or so. It's still about half an inch short of seating. All I can think of is that the original was held in with some kind of locking compound, and that there is some residue inside the bar, which is obstructing the new bolt. Would this be a fair assumption, and if so, is there any easy way of clearing it out, or do i just continue working the new one in a bit at a time?

Alan

Do you know you lost the whole original bolt any chance it sheared off at half length.
If it is not sheared off and it is compoumd i would suggest running a thread cutting tap down the hole. the problem with trying to push the thread compound away is in a blind hole you just push it to the bottom.. If no tap available as soon as the bolt gets stiff take it back out. blast air into the hole to try and blow chipped off compound out. Be slow steady and gentle or you could strip the threads.
RS

 

[Little-Brit]

Alan,

It certainly could be but I also believe that two bolt lengths have been used, I just can't remember why! The only reason I know that much is because I fitted a throttle lock on my 06 GS and the instructions referred to the fact that earlier models (I think) used a shorter bolt that would need replacing with the longer version for this device.

Check that the threaded hole is deep enough for your new bolt, stick a pen or similar up there and also try to establish that the thread itself goes all the way down. If so try persevering with you stiff bolt. If there is loctite in there you will smell it as the force of the bolt heats it up! If you think it feels to stiff withdraw the bolt, any physical damage would suggest that the hole is not threaded deep enough for your bolt.

I hope this drivvle helps.

Derek