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Old 05-27-2009, 11:07 PM   #1 (permalink)
Throttle Jockey
 
DrBob's Avatar
 
Join Date: May 2004
Bike: several
Location: Decatur, GA
Posts: 3,364
Default If you have a bike with internal handlebar wires...

Take a few seconds to check them every now and them! I had not checked the ones on my Intruder 800 in about a year, and when I did check them there was no sign of cracking around the holes that wires go through. But today my handlebars split wide open between the risers, with only about a 1/4 inch of metal left connecting the two sides. Not one of my happier moments in the saddle of an 800.




I pushed forward on the bars to keep the last bit from breaking, and limped it on back to my shop. Luckily this happened only about 2 miles from a nice new wire feed welder I recieved as a gift a couple months back from a wonderful female friend of mine, so I was able to weld the two parts together as a temporary fix until I get a new set of bars installed this weekend.

The bike has only about 76,000 miles on it, a far cry from the 135,000 I racked up on my first VS800 with no handle bar cracking, so I sort of forgot about checking them regularly. I am just thankful it happened only 2 miles from the shop, not when I was out in the middle of nowhere on my California trip a couple weeks ago.

Anyways, if you have an older Intruder or any other bike with internal handlebar wires, check the holes where the wires go in between the risers for any signs of cracking, and if you see ANY, replace the bars.