GgarryP
Elite Member
I wanted to install Acerbis hand guards and needed to remove the handlebar weights. There are several good posts here about that but they require removing the hand grips. This site was helpful because it had great photos. But I can't easily remove or roll back the hand grips since I have heated grips installed by the previous owner. Some have resorted to more destructive means to get the internal weights out.
Here is a photo from the site linked above showing the internal weight with the spring clip. You can see the retaining tabs on the top and bottom and the outer tabs on the end.
The internal weight is held in place by the spring clip with three pairs of tabs. One pair of tabs engage a groove in the weight. The outer tabs catch the end of the handlebar tube and prevent the weight from going too far. The third pair of tabs (retaining tabs) spring into small holes in the handlebar to lock the weight in place. Normally, by removing the grips, these tabs can be pressed in and the weight pulled out.
Caution - Safety glasses recommended.
After studying the design of the retaining tabs that hold the internal weights I came up with a devious plan. After removing the outer weights, I used a blunt shaft (3/8" socket extension) and mallet to drive the weight further into the handlebar by about 1/4". No further is needed. Note - One or both of the outer tabs may break off.
By pushing the clip further into the handlebar, the locking tabs were squeezed flat and disengaged with the holes in the handlebar. I then used a flat screwdriver to rotate the clip just enough so the tabs don't line up with the holes in the handlebar. In one case I could twist the screwdriver between the clip and the weight to move the clip. On the other bar I had to angle the screwdriver and tap it against one of the outer tabs to persuade the clip to rotate.
I then threaded the screw from the outer weight into the internal weight as far as I could. Make sure you have good thread engagement to prevent damage. I placed a pair of vice grips (or a wrench) around the screw shaft just under the head and tapped with a mallet. It took only a few moderate whacks and a little persuasion to slide the internal weights out. Once I knew it would work it took less than five minutes.
I hope this helps some of you.
Here is a photo from the site linked above showing the internal weight with the spring clip. You can see the retaining tabs on the top and bottom and the outer tabs on the end.
The internal weight is held in place by the spring clip with three pairs of tabs. One pair of tabs engage a groove in the weight. The outer tabs catch the end of the handlebar tube and prevent the weight from going too far. The third pair of tabs (retaining tabs) spring into small holes in the handlebar to lock the weight in place. Normally, by removing the grips, these tabs can be pressed in and the weight pulled out.
Caution - Safety glasses recommended.
After studying the design of the retaining tabs that hold the internal weights I came up with a devious plan. After removing the outer weights, I used a blunt shaft (3/8" socket extension) and mallet to drive the weight further into the handlebar by about 1/4". No further is needed. Note - One or both of the outer tabs may break off.
By pushing the clip further into the handlebar, the locking tabs were squeezed flat and disengaged with the holes in the handlebar. I then used a flat screwdriver to rotate the clip just enough so the tabs don't line up with the holes in the handlebar. In one case I could twist the screwdriver between the clip and the weight to move the clip. On the other bar I had to angle the screwdriver and tap it against one of the outer tabs to persuade the clip to rotate.
I then threaded the screw from the outer weight into the internal weight as far as I could. Make sure you have good thread engagement to prevent damage. I placed a pair of vice grips (or a wrench) around the screw shaft just under the head and tapped with a mallet. It took only a few moderate whacks and a little persuasion to slide the internal weights out. Once I knew it would work it took less than five minutes.
I hope this helps some of you.
