Removing Bar end weights

[kruzuki]

I'm having trouble getting the bars ends off my '01 Kat.
I've tried my impact driver, but those damn screws just don't seem to want to budge.
I'm afraid if I twist or smack them any harder, I'll knock the bike over!

Any suggestions?

["K"]

Spray some WD40 into the bolts, peel back the grips and spray some more into the handlebar. Let sit for a few hours and try turning the bolt and barend weight together.
It the barend weights are similar to the ones on the Bandit, do not back the bolts out all the way, back the bolts out maybe 1/4" and use a rubber mallet to hit the bolt into the barend weights to loose the rubber washers inside handlebar, then spray more WD40 into handlebar to try and get the barend weights out.

[steves]

The bandit bar ends are compression mount. So far as I remember... on the kat there's a threaded insert inside the handle bar.

I'd suggest getting a socket-allen wrench to remove it if it's being really stubborn.

[Mojoe]

+1 to turning the weight the same time as you are turning the screw. I had to use a pipe wrench on mine.

[teddy]

strap wrench or pipe wrench usually does the trick

[HemiKat]

Mine wouldnt come loose, they ended up stripping the heads off, so I had to drill the end of the screw out. Then the bar end weight slid off and I could use vice grips to get the rest of the screw out.

[Islandsteve]

put a (preferably metal) pipe/tube on the end your hex/allen key and use it for extra leverage. Wikipedia - Lever. Hex bit sockets also work well ;

Screws/bolts that have been in there for a while often need 'impact driver' like torque to remove. Just put a tube for leverage on the end of your hex/allen key (i have an old scrap 1.5' long steel pipe i use). Use a sudden jolt or burst of "torque/strength" to break the bolt free. I find that even extreme strength applied at a slow rate will yield an unwanted outcome sometimes :P

[Cheriff]

+1 to turning the weight the same time as you are turning the screw. I had to use a pipe wrench on mine.

+1

Then buy a new stainless steel set from me with a socket head cap screw and never worry about this again

[JokerZwild]

+1

Then buy a new stainless steel set from me with a socket head cap screw and never worry about this again

So long as they come with those nifty LEDs im game!