Handlebar snapped - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 30 (permalink) Old 5-13-2019, 8:49 AM Thread Starter
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Handlebar snapped

My handle bar snapped along the red line. What is the best way to fix it? Can someone provide a link to what I will need.

This is an older picture of when it started to bend. The handle bar snapped completely off and is only attached by the break and throttle cords.
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Last edited by Mako; 5-13-2019 at 9:10 AM.
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post #2 of 30 (permalink) Old 5-13-2019, 9:06 AM
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I have no idea what you mean by the red line but you will need a right hand handlebar assembly by the sounds of it. I imagine ebay and the likes will be littered with these kinds of things used, just make sure you dont end up with another bent one. Im not recommending it but if you are comfortable with the part being repaired then maybe go that route. Without pictures its hard to say really.
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post #3 of 30 (permalink) Old 5-13-2019, 9:11 AM Thread Starter
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Sorry about that, I forgot the picture. This picture is a little old. The whole bar snapped and is now dangling.
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post #4 of 30 (permalink) Old 5-13-2019, 11:24 AM
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Kaw part number 46003-1390 for bar only, same left and right. You can get a used assembly either side on Ebay cheap enough. Same 94-09 Gen 2.

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post #5 of 30 (permalink) Old 5-13-2019, 12:42 PM
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I just had to do the same thing actually, just left side so it was a little easier to replace. As mentioned all you need is the handle. I went for new because almost all the ones on eBay were already bent. Found on Partzilla for $40, and $8 (2-5 day) or $10 (1-3 day) shipping.

I removed mine days before and removed my bar end (manual impact screwdriver) and grip to reuse ($30 new for bar end, screw and grip). New handle took about 10 minutes to install and I was on the road again.

https://www.partzilla.com/product/kawasaki/46003-1390

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post #6 of 30 (permalink) Old 5-13-2019, 4:13 PM
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He has one of the welded bar/stanchion ones he need to replace the whole stanchion/bad . Ebay is your friend

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post #7 of 30 (permalink) Old 5-13-2019, 4:35 PM
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Ah.. Now I see what you meant by the red line.
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post #8 of 30 (permalink) Old 5-13-2019, 4:48 PM
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As you can see ...mine broke in the same spot just on the other side...
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The Edge... there is no honest way to explain it because the only people who really know where it is are the ones who have gone over. -H.S.T
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post #9 of 30 (permalink) Old 5-13-2019, 9:58 PM
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OP, what caused the initial strain and final breakage? I am wondering how much the bars can take since I assume normal clip-ons would rotate (perhaps punching the tank), and flat bars would have less stress from bending.
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post #10 of 30 (permalink) Old 5-14-2019, 8:16 PM Thread Starter
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Thanks I ordered replacement bar. Now I need to get the steel stick off.

I think the original strain was from dropping it. Someone said something that it looked bent. That is when I noticed it being cracked. After pushing it a little it came completely off.
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post #11 of 30 (permalink) Old 5-14-2019, 10:03 PM
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Quote:
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Thanks I ordered replacement bar. Now I need to get the steel stick off.

I think the original strain was from dropping it. Someone said something that it looked bent. That is when I noticed it being cracked. After pushing it a little it came completely off.
JB-Weld? If you can pull the triple clamp and take a torch to it that may be the easiest.
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post #12 of 30 (permalink) Old 5-15-2019, 4:16 AM
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Quote:
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I think the original strain was from dropping it. Someone said something that it looked bent. That is when I noticed it being cracked. After pushing it a little it came completely off.
Im not entirely sure what I can see in the area of that break? Has it been repaired before?
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post #13 of 30 (permalink) Old 5-15-2019, 10:23 AM
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Quote:
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Thanks I ordered replacement bar. Now I need to get the steel stick off.

I think the original strain was from dropping it. Someone said something that it looked bent. That is when I noticed it being cracked. After pushing it a little it came completely off.
Oh my what is all that spooge on there? Is that the steel stick? Afraid if you cant get the inside piece of the handle out you have to the get the holder/riser too (46012A).

Yes it looked bent already in the first pic you attached. They are aluminum so they are made to bend and take the force out of the fall.

The Edge... there is no honest way to explain it because the only people who really know where it is are the ones who have gone over. -H.S.T
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post #14 of 30 (permalink) Old 5-15-2019, 2:16 PM
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Quote:
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Yes it looked bent already in the first pic you attached. They are aluminum so they are made to bend and take the force out of the fall.
The risers are aluminum, but the bars and bar ends are steel. The risers are quite burly and don't easily bend or break in a crash, but the bars certainly will.

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post #15 of 30 (permalink) Old 5-16-2019, 5:04 PM
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Quote:
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The risers are aluminum, but the bars and bar ends are steel. The risers are quite burly and don't easily bend or break in a crash, but the bars certainly will.
Seems like it might be the other way around? I came across Fogs comment about them being Aluminum here: https://www.ex-500.com/15-suspension...handlebar.html

Not that it really matters much either way , they still break and get replaced is the point. :P

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post #16 of 30 (permalink) Old 5-16-2019, 10:11 PM
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I broke mine too. It was a hit but small.
Essentially the OEM bars are inexpensive. I can see the seam in the weld that is not deep enough and it is where it snapped.
Get an adapter and quality aftermarket bars, ideally adjustable. I guess it depends on your budget and what style of ridding you do.
If you want to repair them I would stub them both and re-weld them or have someone weld them with a proper weld job. then finish however you want.

BTW if you are in the middle of nowhere and you break the bars one can take the controls off, turn the bar around and bolt the bar on the
other end where the weights are using the same bolt from the weights. This is not to ride permanently but to carefully get you home.
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post #17 of 30 (permalink) Old 5-17-2019, 11:17 AM
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The bars are definitely the manufactured weak point to prevent more stuff up the line breaking or bending.

Far as what the bars are made of, I'll say this, lots of my spare bars has crusty brown rust on them. Aluminum does not produce brown corrosion. I'll stick a magnet to one when I get back home on Sunday to remove all doubt. They're also awfully heavy to be aluminum.

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post #18 of 30 (permalink) Old 5-18-2019, 5:32 AM
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Using steel for the straight handlebar section makes it heavier and in theory will also reduce vibrations through the grips.
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post #19 of 30 (permalink) Old 5-20-2019, 8:04 PM Thread Starter
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Thanks I got new handle bars. Is this piece suppose to go to the left or right? It seems much bigger then the all the current pieces.

What is the left piece called? I want to get a new one if this piece goes on the right.
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File Type: jpg 3E33DEC8-6FC1-4125-B8BD-B5DEC9B41E36_1558397138380.jpg (282.2 KB, 26 views)
File Type: jpg 7331514A-877D-4A26-BC08-582403BA45AB_1558397152306.jpg (274.9 KB, 25 views)

Last edited by Mako; 5-20-2019 at 8:07 PM.
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post #20 of 30 (permalink) Old 5-21-2019, 12:56 PM
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First, my magnet has verified the bars are made of steel.

Now, on to your question. What exactly are you talking about? If you're referring to that silver aluminum piece you got, that's an adapter for aftermarket clip-on style bars. Since you have stock risers and bars, it won't work with anything you have.
Got a picture of the handle bar you bought?
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post #21 of 30 (permalink) Old 5-21-2019, 1:53 PM
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Im still in awe of that attempt at a repair tbh. Man that is bad to another level
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post #22 of 30 (permalink) Old 5-21-2019, 2:48 PM
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Quote:
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Im still in awe of that attempt at a repair tbh. Man that is bad to another level
Sometimes you gotta do what you gotta do. I've made some pretty darn hideous repairs on all sorts of stuff just to keep me going until parts arrive.

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post #23 of 30 (permalink) Old 5-21-2019, 4:54 PM
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Quote:
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Sometimes you gotta do what you gotta do. I've made some pretty darn hideous repairs on all sorts of stuff just to keep me going until parts arrive.
I hear that...I limped mine to gas station, left arm rested on the tank holding the broken bar and clutching when needed, riding basically one handed, bought a skinny roll of duct tape and criss-crossed it up to hold the bar mostly in place, then babied it the rest of the way home.

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post #24 of 30 (permalink) Old 5-22-2019, 4:58 AM
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Sometimes you gotta do what you gotta do. I've made some pretty darn hideous repairs on all sorts of stuff just to keep me going until parts arrive.
A: I wouldnt have ridden it in that state. B: I wouldnt have attempted to repair it that way even if that was the only option at the time.

There is 'making do' to get a bike running and there is this kind of thing. Worlds apart
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post #25 of 30 (permalink) Old 5-22-2019, 11:01 AM
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A: I wouldnt have ridden it in that state. B: I wouldnt have attempted to repair it that way even if that was the only option at the time.

There is 'making do' to get a bike running and there is this kind of thing. Worlds apart
Neither would I, but it is what it is.

Right now, I'm more worried about the OP getting all of what appears to be JB Weld off of there. That stuff does not come off easy.

1990 EX500 - 140,000 miles as of May 27th, 2019
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