Maintenance & Technical > KX500 Original

tusk D-flex mounting

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kaw rider:
use a wheel cylinder hone on the throttle tube.

maddoggy:

--- Quote from: BDI on May 02, 2010, 08:16:16 AM ---Thats crazy that you were able to stretch them in the first place. You almost need some sort of sizing die. If you could find something with a 7/8 inner to hammer on to the bars but then you will pay hell getting it back off. You might just consider buying new bars.

--- End quote ---
yah, i think the die crimping is the only way to go so the integrity of the bars won't be a question. i really don't like the idea of taking material off by any method even though i only need .030 or .040 probably. i'll let you guys know what i decide to do and whether or not it worked. i did think about new bars, but other than this little problem, they are in perfect condition. i'll try a fix before replacing them.
                                                                              maddoggy

cutting torch:
I like the hose crimper idea myself. I've done that before with great results on aluminum and steel with a Gates crimper. I have not done it on bars, but I don't see the harm in doing it out at the end.

torch

BDI:
these are only a couple bucks :| maybe you could squeeze it back.

maddoggy:
i was in the garage last night, looking at stuff i cant due now that my wrist is broke, and i took a good hard look at the new handguards. i cant believe i didnt see it before, but the end of the throttle tube was touching the dang handguard. very slightly but it was touching. so i took a bare hacksaw blade and twenty lefthanded minutes later KABOOM, everything is golden now. i swore what i felt was drag on the inner part of the tube. now i feel like an idiot for not giving the problem the proper diagnostics. sorry guys but thanks for your input.

                                                                                                                           maddoggy

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