Handle Bar Stem Wedge Stuck (sigh)

wild

wild

Well-Known Member
Moving right along the teardown of this 86 SR500, I've arrived at a handlebar stem that won't budge. I removed the bolt after unsuccessfully trying to tap it down and free the wedge, and made a puller for the bottom of the fork to try and separate the wedge by pulling it down. I believe it has grown to the aluminum tube. Anyone with a fool proof idea for removal?

On a side note, I found the cross bolt for the shifter mounts is made of carbon steel and badly rusted. Can those be bought readily in stainless?
 
black lightning 1987

black lightning 1987

Moderator
Staff member
I've never had a wedge that couldn't be moved by loosening the bolt and tapping it with a hammer. Did the stem come out?


The cross bolt might be hard to remove from the pot metal boss without breaking the threaded end off the boss. If it's still in the boss I would give it a good coat of grease and use it as is rather than risk breaking the boss. I'm not sure of the thread but you can buy lengths of stainless all thread in metric and inch sizes on eBay.
 
wild

wild

Well-Known Member
Not only did I tap it with a hammer, I beat it with a big hammer, pulled the bolt and made a puller for the other end through the forks and beat while pulling. Nada. Now I've started drilling the wedge away, hoping that the stem will pull out after the wedge is gone. I'm not overly optimistic though, the forks are not aluminum, so there could be some galvanic action with the stem at play also. so far, the only good thing is the seat came out easily. LOL
Handlebar.jpg

Handlebar3.jpg
Handlebar2.jpg
 
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black lightning 1987

black lightning 1987

Moderator
Staff member
Did you try knocking the wedge in both directions? Was the bit of wedge that you got out steel? The fork steerer tube is steel. Guessing that you may end up cutting the stem off and sawing the quill through. I've had to do that with stuck seatposts. Tedious work but end result is worth it.
 
wild

wild

Well-Known Member
black lightning 1987 said:
Did you try knocking the wedge in both directions? Was the bit of wedge that you got out steel? The fork steerer tube is steel. Guessing that you may end up cutting the stem off and sawing the quill through. I've had to do that with stuck seatposts. Tedious work but end result is worth it.
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I did try that at first, but the pieces that are coming out now show rust at the outside. I ended up drilling the hole out as big as I could, then drilling a pilot down one side to thin it out more. A small punch forced between the tube and the wedge is breaking it into manageable pieces. I'm just hoping the stem has not bonded to the steel tube. It will be out today just after a quick ride on my old beater to get the blood flowing.
 
wild

wild

Well-Known Member
I finally got it to move in the right direction after many judicious taps with a hard-faced hammer. Although I destroyed the wedge, the stem is still in pretty good shape under the corrosion. Thanks for the support and encouragement!
Handlebar4.jpg
Handlebar5.jpg
 
wild

wild

Well-Known Member
black lightning 1987 said:
The bike must have spent a lot of time outdoors. I've never come across anything that looked like that. I hope the fork is safe to ride.
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No damage to the fork that a little cylinder hone won't cleanup. The environment in this area is coastal with a good bit of salt in the air as you get closer to the ocean. Fortunately, most of the parts I've removed with the exception of the crank bearings are reusable.
 
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