FZRSupport: the FZROnline Archive

On my latest MOT they said that the handlebars should have less or no slack. Right now I'm able to wiggle the handlebar ends about 5-10 mm up and down. From the repair manual or parts catalogue it's not really apparent what could cause that or more precisely, what holds them tight except the handlebar boss screw (which is tightened).

Any ideas?

No ideas?

They are a taper fit in the boss that clamps the fork tube. There is an allen screw that comes in from the opposite end of the bar end weight. Check these to see if loose.

To clarify: The whole handlebar assembly seems a tiny bit loose - handlebar is tight in the boss, but the boss has some slack, although the boss screw is tight.

sounds like the fork toobs are clamped at each yolk and this is stopping the main stem from clamping up

if you loosen the bottom yolk pinch bolts that hold the forks, then adjust the main stem/bearing pressure and finally re-tighten the bottom yolk pinch bolts. This should sort out the free play

The tightening sequence is in the mainual that you can down load from the link at my place
http://www.exup1000.co.uk/tech/fzr1000r/index.html

Handlebar assembly (handlebar + boss). Not the forks, not the stem, not the handlebar in the boss.

A picture to clarify - this is what moves:


Not much, the boss itself less than 1mm, the handlebar end ca. 5-10mm.

There are rubber dampers fitted inside the boss at top and bottom; are they fitted ?
http://www.cmsnl.com/yamaha-fzr1000w-19 ... ml#results
The fixing bolt in the original top yoke should prevent any movement of the boss on the fork stanchion.

On further inspection of your pic;
Does the boss fit the fork tube/stanchion tightly. ?
It should be nearly an interference fit (as in tight) ; yours looks to have had an attempt to open it out by
some means (perhaps to fit something larger).

That image was linked from Google image search, it is not mine. I haven't taken my handlebars apart yet.

Visually, I can see that both the dampers and the plate washer are in place. Could the dampers be worn out? I guess it would be too much to expect the garage report something like that when I had the fork seals replaced last year, when they even failed to notify that one rear brake caliper bolt was missing (which is why I started doing the repairs myself from that on).

I'll try to snap a picture of my handlebar later in the evening.

by Kevadlilleke » Fri Jul 04, 2014 8:33 am

That image was linked from Google image search, it is not mine. I haven't taken my handlebars apart yet.

Post back when you have some images..

Googled image was linked to stop the confusion as to what moves and what doesn't.

Illustrative picture of the movement:


Purely decorative picture with no quality (it was the best light I could master at given hour)


Right now my best bet is to wait for steering bearing inspection mileage to come by and just see what's up in the course of that. Seems like something that is hard to analyze on the forum.

Your fork stansions (tubes) are slightly too low in the yokes. See the circlip/washer/damper rubber not enough crush on them.
Loosen all the yoke pinch bolts, push them up hard as you can by hand, check stickout same both sides, tighten. Will only need a mm or two.

coops wrote:Your fork stansions (tubes) are slightly too low in the yokes. See the circlip/washer/damper rubber not enough crush on them.
Loosen all the yoke pinch bolts, push them up hard as you can by hand, check stickout same both sides, tighten. Will only need a mm or two.

I've already suggested checking the tightening procedure but got knocked into touch

Stig wrote:

coops wrote:Your fork stansions (tubes) are slightly too low in the yokes. See the circlip/washer/damper rubber not enough crush on them.
Loosen all the yoke pinch bolts, push them up hard as you can by hand, check stickout same both sides, tighten. Will only need a mm or two.

I've already suggested checking the tightening procedure but got knocked into touch

So you did stig. Sorry I missed your post.

This will probably sound as stupid as I think it it will, but... There's a circlip somewhere on the fork stanchion that should support the washer?

Based on the parts catalogue I was under the impression that it's all the way smooth and the only thing holding the boss was the boss screw. I guess I'll have to open it up to see for myself, as I just couldn't find a good image of the stanchion top end on google image search (yes, that's my first go-to when looking for information).

EDIT: Can anyone link to a part number if it turns out I have no circlips?

cant find a part number but its just a clip of thin guage spring wire a bit like a circlip