GZ250 'throttle cap tightener bolt'

[TXtwowheeler]

The long thin bolt running into the handlebar through the throttle and through the cap on the end of the handlebar rattled loose. I was trying to tighten it back in, but way down 4 inches inside, the piece that's supposed to receive the threads got pushed too far in when I was trying to get the threads started. Now I can't reach it. The cap is off, and I can't get it back on until I get the piece back out where I can reach it.

First: Any tricks to getting it back out?

Second: Any tricks to avoiding having it rattle loose again?

I'm pretty handy, and have a moderate assortment of automotive tools, etc, but new to bikes.
Thanks in advance for your help.

[music man]

Are you talking about the black bar ends?

[Easy Rider]

Originally Posted by TXtwowheeler

The cap is off, and I can't get it back on until I get the piece back out where I can reach it.

First: Any tricks to getting it back out?

Second: Any tricks to avoiding having it rattle loose again?

Last question first: Blue locktite.....or a little fingernail polish. And when you put it back on, do NOT overtighten. Very snug is about right.

First question: It depends on what pieces are IN and which ones are OUT. If you have the rubber expansion plug OUT, then with the help of a friend you should be able to lean the bike over to that side and shake the nut (and washer) out of the bar end.

If (more likely) you don't have the rubber plug out, then things get more difficult. First, try the bolt by itself, without the weight.
Failing that, a coat hanger with a tight hook at the end might work.
Third option would be a long lag bolt (wood screw) about the same size as the assembly bolt.

I think probably the best thing you can do is to remove the OTHER one so you can see exactly how it works. Loosen the bolt/screw just to the point where it feels loose; NO FARTHER. Then get a firm grip on the weight (or bolt or both) and PULL/wiggle the whole thing out of the bar. The whole thing comes out as an assembly, not in individual pieces.

Good luck!

[TXtwowheeler]

Thank you for replies. I'm going to try the coat hanger with tight hook. The plug is down in there so shaking it out won't get it.

Yes, it's the bar end. I'm not well-versed in the part names. I noticed in pictures of other people's bikes, that it's not a problem unique to me. Thanks to all for help!

[Dupo]

Coat hanger can work. Ive done it once. 2nd time i had to saw the bars in half and buy new bars from a local bike shop.

[Easy Rider]

Originally Posted by Dupo

Coat hanger can work. Ive done it once. 2nd time i had to saw the bars in half and buy new bars from a local bike shop.

You are serious aren't you?
You were wanting to change the bars for another reason, weren't you ?? :??:

I can't imagine anybody really doing that......just to get the rubber plug, nut and washer out of the bars.

Before doing that, I would first find a long lag bolt about the same size as the assembly bolt. It should "catch" the hole in the plug and enable you to pull it out.
Failing that, I would just leave them in there and get a new bar-end weight assembly. It can't be THAT expensive.

[Dupo]

Uhhhh yea i am serious. On the old GZ i had ..... took the bar end off and that dam piece fell in, all the way in. Couldnt get it out by tilting the bar. One side came out by grabbing the plug with a coat hanger and the other one grabbed but kept getting stuck.

I sawed it in half to get the plug and nut out. Nut fell in and the plug got pushed in too far. Those plugs get f'king stuck ... try it some time.

The bars were probably as cheap as new bar ends quite honestly. The GZ has very simple design .. cheapo bars.

[Canuck]

YES FINALLY someone else did it and brought it to this forum!
wanted to save myself the embarrassment.... hahaa!!
so the cheapest fix is to Saw the bars off get new ones... and recover the lost pieces?

[Easy Rider]

Originally Posted by Canuck

so the cheapest fix is to Saw the bars off get new ones... and recover the lost pieces?

I suggest that you price the parts and make that judgement for yourself. I am skeptical.

Some of us that have LOTS of mechanical expertise tend to ...mmmm... forget what it's like for someone who doesn't. :roll: :biggrin:

[music man]

The only draw back to leaving them in there(the hardware to the bar-ends) is I ended up doing that and I can hear them rattling around in there from time to time.