Basic Maintenance: Handlebar Weight Assembly Replacement

[rdprdp01]

I recently documented the damage to my motorcycle when I crossed paths with a Tesla Owner in a Whole Foods Parking Lot. I have somewhat managed to channel my amazement and rage by enjoying the quality time spent repairing my motorcycle. 

This thread documents how to replace a damaged Handlebar Weight Assembly. Note that this assembly plays a very important role in enhancing our riding experience. They reduce handlebar vibrations from the engine and the road. They also improve stability by decreasing muscle fatigue in your hands. They are a “have-to-have,” not a “nice-to-have,” regardless of what any Internet influencer may assert.

See the most common scenarios when a handlebar weight replacement is warranted:

• Damage from a Drop or Crash: If the handlebar end has been scraped, dented, or bent during a fall or accident, the weight should be replaced to restore structural integrity and balance.
  
• Missing or Loose Components: If the weight has fallen off due to vibrations loosening the screw, or if the internal threads are stripped.
  
• Significant Corrosion or Rust: If the part is heavily corroded, it might prevent it from fitting properly or affect its function.
  
• Damaged Rubber Dampers:  If the rubber has deteriorated or hardened, it may cause the weight to vibrate, requiring a replacement of the weight or its mounting rubber.
  
• Excessive Handlebar Vibration: If you experience new or increased tingling/numbness in your hands while riding, it may indicate a damaged or ineffective bar weight.
  

Please note that although I experienced something akin to dropping a motorcycle in a garage, the entire assembly was damaged, and the snap rings was completely obliterated from the weight and momentum of the motorcycle landing on the bar end weight. I suspect this was the result of my decision to hard stop, hold the handlebars firmly, and try as best I could to have the force of the impact centered on the handlebar weight:



Here is how I went about replacing it. As always, defer to the professional mechanics if someone gently calls me out for a needless or questionable step!

Step 1: Source a diagram that details the Handlebar Top Bridge of your motorcycle. Make sure you specify the year, make, and model of your motorcycle. Honda designers are slightly mischievous. They have been known to make minor changes between model years. I use Revzilla:



Step 2: Procure the six replacement parts before you remove the handlebar weight assembly:

• 11: HANDLE WEIGHT RUBBER A: (53106-KR3-770)
  
• 9: HANDLEBAR WEIGHT B: (53105-KV3-000)
  
• 11: HANDLE WEIGHT RUBBER A: (53106-KR3-770)
  
• 12: HANDLE WEIGHT SNAP RING (53108-KR3-940)
  
• 10: HANDLEBAR WEIGHT (53105-MEJ-720)
  
• 20: 6X65 OVAL SCREW (90191-MK6-6700)
  

There is a possibility you will not be able to reinstall a damaged assembly. Hence, order everything first and check part numbers closely.

Step 3: After you have received all the replacement parts, remove the damaged assembly.  Turn the oval screw counterclockwise to remove the external handlebar weight. Make sure you support the handlebar weight while you are disengaging the screw. There is a good chance the screw will be bent. Make sure you have the proper bit and that it is flush with the screwhead. Turn slowly while applying a constant pressure on the screw:



Step 4: After removing the handlebar weight, insert the oval screw back into the assembly and tighten it again by turning clockwise. Turn the screw until it is as fully inserted as possible. Do not overtighten the screw. We want it snug but no more.



Step 5: Using a pair of vice grips or pliers, attach to the screw and pull the assembly out of the handlebar. Make sure you are aligned with the handlebars as you pull. We want the damaged assembly to slide out with as little effort as possible.



Step 6: Inspect the assembly. In my incident, the force of the motorcycle slamming to the ground crushed the retention metal clip! Old nerd that I am, I calculated the gravitation and kinetic force of a 550 lb motorcycle going four miles per hour with a 150 IB rider with a downward dejectory of 3.5 ft. I believe the impact resulted in 19,442 lbf (foot pounds of force). That is the equivalent of 6 average-sized cars or a small aircraft!!!!



Step 7: Clean the inside of the handlebar and remove whatever debris may be left in the tube. I improvised by taping a heavy cloth to a screwdriver and inserting it into the handlebar tube. I turned and turned and withdrew the screwdriver and found the remnants of the metal retention clip, which had been turned to metal shavings/powder from the force of the fall:







Step 8: Assemble the handlebar assembly and add a small amount of lubricant to the rubber end caps. I use white chain grease, but I suspect any lubricant that will not corrupt the rubber over time will do just fine:





Step 9: Insert the new assembly and, using a rubber mallet, gently insert it into the handlebar tube. Note that the handlebars may have been slightly damaged, too. Go slowly and do not apply too much force. Trust your instincts. The new assembly will either go in with a gentle push or not at all:





Step 10: Assuming all is well, place the new bar end weight on the assembly and tighten the screw to 6.6 ft-lbs (about 9 N·m). I recommend using blue Loctite to help keep things properly secure but it is unclear to me if this practice is widely followed or another example of me making things more complicated than necessary!



It is a wonderful feeling to see the bar weight properly secured and pristine once more. Here’s hoping you never run afoul of a Tesla in a parking lot! Have a great week. David

[pdedse]

I hope I never have to, but good to see what was done just in case. Very nice photos.

[Gone in 60]

Nice review! I repainted mine when I got my CB1100. The bike hadn't tipped over, but the black bar ends were a bit scuffed from the owner's cover rubbing on them.

[peterbaron]

A minor surgical procedure in the garage...and without anesthesia....and as usual, always supported by photos, good job, David.