Any help gratefully received:
I’ve just bought some Acerbis hand guards for the Hornet as part of my efforts to get some sort of feeling in my fingers . . . but they are fitted by taking out the bar weights inside the actual handlebar out and refitting with theirs. Instructions that come with them are appalling and, after talking to the reseller, they said simply waggle them about and they will pop out – not true!
Does anyone have any idea how to remove these?
use a screwdriver??
i have a haynes manual at home (CB600F/CBF600 
) so will check for ya if you dont figure it out by then
should be a philips head screw you need to loosen off first. then if they won’t pull out, put a close fitting ring spanner round the bar weight so it’ll catch on the edge and give it a tap with a hammer. may have to be a fairly firm tap to remove it but it will come out. this is from memory so may be a little hazy - don’t think you want to completely remove the screw either as it may leave the weight in the bars. hope that helps mate 
i’d do yourself a favour and sling some renthal ultra lows on it too. much better than standard bars. dunno if your brush guards will fit in em though as they’re smaller diameter than the stock monstrousities.
Thank you both for coming back to me – Ad, the Philips screw, would that be under the gripper rubber as I have heated grips fitted by the previous owner and I may have to muller these to get to the screwhead (makes sense as they ain’t budging at present)?
Pang, if you can confirm where this screw is via the manual that may well help me actually abandon this or come up with some creative new fitting method!
Thanks fellahs.
Zeus,
The phillips screw ( or it could even be a hex bolt) should be in the centre of the bar weight on the outside edge (i.e. as far as you can get from the forks). They usually work by screwing into an angled disc which locks the weight into the inside of the handlebar when tensioned by the screw. You should be able to undo the screw a few turns (to release the tension) and then wiggle the bar weight out.
I dont think this should affect your heated grips as they will be glued to the outside face of your handlebars, but you may have to modify the ends to release the bars grips.
Hope this is clear, if not come back to me…PH
yeah that’s it, at the end of the bar. you could cut a circle out off the flat end, the width of the bars or take the grips off. to take em off; get some wd40 with the straw attached and pop a flat head screwdriver under the grip. lift the grip up so you can get the straw in and spray a bit. work the screwdriver slowly round the grip whilst spraying and you should eventually be able to slide it off. be careful though coz of the elements in the grip (actually i dunno if cutting the ends would be a good idea in case and elements are routed through there). that’ll reveal the bar end in the end of the bars (logical eh?). then follow steps from other post.
alternatively you could just buy some bar muffs 
Fantastic – thank-you – I’m going to give it a go in the morning and, if I come unstuck then the worst thing that could happen is that I bugger up the heated grips. Hopefully I’ll be able to get to the screw/bolt without damage.
Thanks again – much appreciated by this technical numpty!
Zeus, the haynes manual didnt provide too much more info that what has been said (and i thought):
that there is a philips screw in the middle that you unscrew to then remove the weight
Thanks Panagiotis – I may have mislead with my description, but I’m after removing the bit this screws into – sorry, I thought the bit at the end was the bar end and the bit in the middle, inside the bar, was the bar weight 
I’m suspecting that under the heated grip is a screw that goes through the bars into the bar weights as neither side is budging by removing the bar end or by loosening the bar end and waggling it about as the reseller suggested.
I’m going to show the entire thing to someone who is far more technically minded than me tomorrow, along with your suggestions, and see if they can suss the situation – luckily temperatures are up tomorrow so an hours ride won’t feel like hell in my fingers!
I thought I ought to continue this story – no-one, including my local Honda dealer, has been able to remove the bar inserts (not weights as previously mentioned, sorry!) – it’s now booked in Monday when they’ll have more time to have another go!
In case anyone has to do this to a Hornet, the bar inserts are held in by two clips that run down the barrel and clip up into the bar – thus preventing them from being pulled out. The only way to get them out is to remove the grips entirely exposing the bar, push the clips in and then pull.
Thanks for all the advice to everyone that posted.
Glad you got this sorted…btw where did you get the guards from?
ps Is this what you mean by the two little holes under the grip ? :
i guess you didnt read the thread i linked to above e? 
:Whistling:
Ha ha – I did read it but couldn’t lift the end of the heated grip (neither could anyone else that tried) without causing damage. According to the honda dealer rather than being a small hole close to the bar end, this is a small slit about half way along and even they have had problems removing the heated grips without damaging them to get to it (I think they have been fitted badly or the wrong sort for the bike). What started out as a quick “something I can do myself” has turned into a lot of faffing and paying for dealer time (and possibly a new set of heated grips if they cannot removed the ones on there without damage!)
The only place in the UK that seem to stock these are AMS: http://www.ams4ktm.co.uk/shop.php?product_id=3466
If mine get fitted tomorrow I’ll let you know whether they work!
Unless I’m missing something here, this is a similar problem the the one I had.
I was able to undo the bar end screws (well, hex. sockets in my case), remove the bar end bits, fit the guards and replace the bar end bits using a slightly longer hex. socket.
Just didn’t disturb the bits inside the bars and made the whole job a Haynes “1 spanner” operation.
Am I missing something?
Ah, we thought of that on Saturday but the diameter of the new hex bolt is a lot larger than the original bolt therefore the hole in the guard is a lot larger – we found a longer hex bolt but because of the bigger hole it wouldn’t stay in position no matter how tight we made it. A friend then tried honing a nylon bush to make up the difference, but that didn’t work because the hand-guard is not flat where it meets the bar insert and therefore rocked slightly . . . I dropped it into the dealer earlier and pick it up at 4, hopefully they’ve been successful and it won’t cost a fortune?
Woo Hoo – I’ve got hand guards . . . at last!
I got charged £55 for fitting them as it took ages to get the old ones off and to remove the copious amounts of glue they’d used to stick on the heated grips.
It’s not cold enough to tell whether they really work, but I do think they are making a difference. I think they look really good too.
The dealer suggested that because the bar inserts are lighter than those removed and lack damping I may get a vibration through the bars at high speeds – haven’t felt anything yet so am very happy.
glad it’s worked out fella. echo the pics request. plus let us know how you get on with them. getting a bit peed of with my bar muffs!
def look better than bar muffs fella
Looks good!
Now some blue Renthal bars on and it will look even better - and you’ll have to start all over again.
Actually, I have a set (Ulra Low 7/8) that the previous owner put on my red Hornet! Find a red pair wand we can do a swap!
