Any tips on bar end nut removal, you know, the nut encased in rubber inside the handlebars? I’ve tried pulling, tapping, oiling and twisting. I’m avoiding removing the grips and heating the bar for now. I certain it’s removable, as it’s available as a replacement part. Looks to be just a rubber cylinder with nut.
It's a wedge type thing. Get a long bolt or a piece of threaded rod the same sized and thread pitch as the regular bar end screw. Screw it in and push and gently pull. Repeat if necessary. It'll come out.
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My OEM inserts were a press fit deal. ThrottleMiester throttle lock bar ends came with a tool that slides over the end of the handlebar tube with a puller bolt that draws the insert out. Without that tool I'd have been looking at the slide hammer option.
I think he's replacing his bar ends and is having an issue after removing the retention bolt.
If I'm understanding this correctly, as you tighten the bolt it will "squish" the rubber piece, which expands and holds it tight from the inside of the bar.
Re-installing the bolt, but not tightening it, you are trying to relieve the tension on the expanded rubber by moving the nut slightly to the interior of the bar. At the same time you want to be working the exterior end to pull it out. That rubber gets "set" after years of being there.
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2008 Yamaha FJR1300AE
2002 Honda ST1100