Signal Light/Handle bar end removal

[jscgdunn]

Hi FJ Nation,
On my '84 I am having signal light switch problems.   Odd thing is that if I hit the horn button it will sometimes work.  At any rate, according to the threads, it looks like need to remove the switch and clean up the contacts and get the dust out etc.   As the choke is integrated it appears I will need to slide the entire unit off to split it.

I tried to remove the handlebar end weight but it appears to be corroded on tight.....using the breaker bar actually twisted the Allen key inside the bolt.  Any advice on how to remove the handlebar ends?  Or If I am on the wrong track about removal of the switch please let me know.

Thanks a bunch,

Jeff

[FJmonkey]

Hi FJ Nation,
On my '84 I am having signal light switch problems.   Odd thing is that if I hit the horn button it will sometimes work.  At any rate, according to the threads, it looks like need to remove the switch and clean up the contacts and get the dust out etc.   As the choke is integrated it appears I will need to slide the entire unit off to split it.
I tried to remove the handlebar end weight but it appears to be corroded on tight.....using the breaker bar actually twisted the Allen key inside the bolt.  Any advice on how to remove the handlebar ends?  Or If I am on the wrong track about removal of the switch please let me know.
Thanks a bunch,
Jeff

If the Allen socket is messed up then you are kind of screwed...You might need an Easy-out kind of tool to back the bolt out and remove the end weight. You might be able to use a Dremel like tool and grind/cut a slot in the bolt and use a large screwdriver to back it off. If you do then replace the bolt with a Torques style bolt, looks like a star pattern rather than a "6 sided waiting to be round" socket. Good luck. You might also be able to turn the screw if you turn the weight with the screw. It might help with the Hex socket being buggered up and all......

[markmartin]

A pipe wrench will do it.  It''ll also put an undesirable horizontal knurl on your bar ends that you'll have to sand off and then repaint.  You can try a rag or mouse pad or anything under the jaws that you think will protect the ends, but if that doesn't work, just a naked pipe wrench (the bigger the better) should take 'em right off.  Good Luck.

[rktmanfj]

I tried to remove the handlebar end weight but it appears to be corroded on tight.....using the breaker bar actually twisted the Allen key inside the bolt.  Any advice on how to remove the handlebar ends?  Or If I am on the wrong track about removal of the switch please let me know.
Thanks a bunch,
Jeff

BTDT.  I used a BF pipe wrench on one of mine, and it was still hard to turn.

If you are careful, and confine the damage to the raised ring part nearest the switch, you can probably chuck the bar end up in a drill press or lathe and smooth out the damage.

Why that part of the bar end was not designed with two flat sides (so an open end wrench could be used) is beyond me.    

Mark - GMTA!   

[jscgdunn]

Thx Everyone,
I have found that a very large pipe wrench or ball peen hammer can solve most probelms in life.

Jeff

[weymouth399]

The bar end has locktite on the threads from yamaha. If it has never or been a long time since it's been off you should use a LITTLE heat to remove. That said the grip needs to come off, because you are heating the bar not the bar end. Just heat, not cherry red, and it should come right off. Then a set of vibranators from RPM Randy. shameless plug

Bob W

[racerrad8]

Then a set of vibranators from RPM Randy. shameless plug

Bob W

Why thank you Bob for mentioning the Vibranators.

There is no shame in that

Randy - RPM

[Pat Conlon]

Bob, did you try heat? Any problems with the throttle tube or sensitive electrics?

[weymouth399]

Pat throttle side you need to be more carefull and heat the barend, wrap something around the throttle pipe to wick the heat away. Again heat, not cherry red. Sm propane torch will do. I was thinking clutch side only
. No electronic to mess up unless you have aftermarket stuff on your bike, (hotgrips) then you should know better. Don't get me wrong I have parted bikes that wouldn't come apart

Bob W

[fj11.5]

+1 on the stiltsons/pipe/monkey wrench  work a treat on the bar ends , if you set the up right they leave hardly a mark as i had the same issue when wanting to change grips when i bought my 84 po had fitted dirt bike grips,waffle pattern  in red  who said it was ok to colour code 80,s bikes