TOPIC:

I recently replaced the bars on my 1982 KZ550 A3, and I just want to make sure I'm not riding a death trap. My previous handlebar was 7/8" diameter, and the new one I ordered is also 7/8".

I put the new bars in place and tightened down the handlebar clamps to the torque spec listed in my Clymer manual, 13 ft-lbs. However, the clamps don't sit flush against the mount underneath, there is a gap of about 2-3mm on each side. I'm not sure if it was like that for my old bars and I just didn't notice, or maybe the tolerances are a little off on my new bars, or perhaps I'm just not cranking the bolts tight enough... 

It feels pretty sturdy, but the gaps make me a little nervous. Should I be worried?

 

A gap between the clamps is correct to allow them to grip the bars without bottoming out but the distance between the bar bends is slightly too narrow and the clamps aren't sitting square.
You really need a set of bars that have a longer straight section between the first bends so that the clamps sit level.

You are clamped onto a curved section of the bars...not good at all.  Like Zed said, you need bars with a wider clamp area.

Good to know, thanks for the info. Do you have any recommendations for a set of bars that are similar to stock, with maybe just a little bit more rise? My clamp area is about 4.8"
 

HardRockMiner posted this. www.z1enterprises.com/clearance/handleba...rols/handlebars.html

Search the internet for how to measure handle bars. Then you can start looking. Endless choices. All personal decision.

Watch all the cheap stuff! Buy a set with the straight grooves, knurled in them. Some of the cheap's like emgo come without the grove for gripping at the clamps.

Not sure what you mean by grooves.  I ran a set of Flanders handlebars for several years & now have been running some Emgo Euros without any problems >> both are smooth >> no grooves or knurls or anything.  same goes for the stock handlebars for my motorcycle.  I think the key is to get a set that's wide enough at the center measurement.  Z1Enterprises doesn't seem to provide that info any more, so you have to check the measurements in the mfg catalogues. 

 

Those are the wrong bars, get different ones. The clamp area is an easy measurement but as for the rest, you need a degree in three dimensional geometry.
In the last picture, are those stress fractures I'm seeing in the paint on the clamp cap?

wrote:

Those are the wrong bars, get different ones. The clamp area is an easy measurement but as for the rest, you need a degree in three dimensional geometry.
In the last picture, are those stress fractures I'm seeing in the paint on the clamp cap?

Not sure, how would I tell?

wrote:

wrote:

Those are the wrong bars, get different ones. The clamp area is an easy measurement but as for the rest, you need a degree in three dimensional geometry.
In the last picture, are those stress fractures I'm seeing in the paint on the clamp cap?

Not sure, how would I tell?

You would have to clean the paint off and look for cracks. Or take the clamp off and see if there are cracks in the half circle area.

No obvious cracks as far as I can tell, but here are some pics if you want to take a look.

It's hard to tell in the picture I referenced but things did look askew. Could be the camera angle. And the fractures I think I see would be at the top, not next to the bar. As Mika says, you'd have to clean the paint.
I only broke one such clamp in my life but it was for the front brake lever. It just broke without warning.