Question 0
That is the correct part number for bar end mirrors for your bike from looking at the parts fiches.

According to the parts fiche that countersunk screw (item #10) should be M5 not M4.

Question 1
Personally I’d be looking to replace that screw anyway if the head has already started rounding, it’ll only get worse.

You could try installing the adapter back into the bars with some blue thread lock, then try undoing the screw. Hopefully the blue thread lock will be enough to stop the insert turning but you can still get it out if you really need to. If you have Torx bits, try finding one which just fits and using that on the screw, it may help more than a hex key. If you have access to an impact driver you could try using that to shock the screw free as well.

Question 2.1
It’s hard to tell scale from your picture but I suspect your cap head screw is actually an M6 which is why it won’t fit. A quick way to tell would be to pull a bolt from an engine casing (e.g. starter cover) and compare, and even see if your cap head screw threads into the bolt hole in the engine casing. If it does, it’s an M6 and it’s too big. Another way to check is to see what the hex key size is for the bolt. A standard M6 cap screw uses a 4mm hex key, M5 is 3mm, M4 is 2.5mm.

If you want to take out the reducer in the bar end, find an appropriate bolt and nut which screw into it, do the nut up against the reducer and you should then be able to turn the bolt to undo the reducer.

Question 2.2
As above, confirm the bolt sizes you have to be sure.

Question 3
That’s weird, I’d expect that shoulder to fit into the handlebar too. If your dealer is nearby and has it in stock, you could ask them to pull out one of the correct adapters for that mirror kit (A9630086) and compare them to see if what you have matches it.

Question 4
No idea, sorry.

 

That's really helpful; thanks.

The larger of the two bolts in the side-by-side picture is definitely M5 -- I ordered them specially since they were missing from the kit. Measuring them confirms -- 5mm.

I hadn't thought of looking at the fiches. Thanks for that. That pretty much confirms that at some point one of the shops my bike's been to replaced the bar end weights and how they attach to the bars, and I just didn't notice. End result is that they're no longer attached with M5.

As for the adapters not slotting into the bars, I suspect I just have the wrong parts. The dealer doesn't have them in stock but says they can order some. Given the issue with the bolt threading it's a trip to the shop by this point anyway.

 

Found the part number for the adaptors I should have, and searched up an image; they should look like this

The difference in diameter between the left edge and the main body there is much larger than on the parts I have:

So yeah, definitely the wrong parts.

 

That sucks, hopefully you can either find the right reducers or just drill and tap them out to M5 to take your bolts. Weird that a shop changed them at some point! There is a supercession on the bolt in the link I posted above but it's for another M5 bolt. Odd.

That's annoying on the adapters as well, maybe it was a mirror kit for a bike with bigger bars so had a different adapter.

 

There is a supercession on the bolt in the link I posted above but it's for another M5 bolt. Odd.

You lost me here!

 

Sorry, that part number at some point replaced/superceded a previous part number. I thought the previous one might've been an M4 screw instead but it's still M5.

 

Ah I see.

Update on my end: my local dealer says their records show they have two of the adaptor parts in stock in their other branch, so I'm waiting on confirmation of that. Assuming they have them I'll go out to get them and at the same time they say they'll have a peek in my bars for me and see what can be done about the thread.

 

When you get the correct bar end adaptors, would you mind posting the diameter of the large section? I'm trying to work out if RS mirrors will fit on them as the RS mirrors are much cheaper

 

I picked up the other adapters which claim to be part A9630086, which is the part specified in the bar end mirrors kit.

Here are the two new ones, next to one of the older ones which doesn't fit in my bars.

And the other way up:

The good news is that the thinner part actually fits in the bar end, though it doesn't seem as snug as I would have expected.

The bad news is that I'm still not convinced it's the right part:

• There's no indentation for the lockwasher like the old pieces have, and the lockwasher is specified in the instructions. So I'm not sure it'd be held securely enough... Maybe I just don't know how lockwashers work though, and the diagram doesn't show an indentation.
• The M5 bolt which I ordered specifically by part number to go with this kit doesn't fit through the hole.

I mean... neither of these really look right do they?

In other news:

While at the shop I asked them if they could separate the bolt+bar-end-weight+reducer unit which comes out all as one from the left handlebar. They had a go. They managed to get the bar-end weight separate but in the process broke the bolt (don't care about that) and made a big hole in the reducer, so that's now toast.

I don't know what to do at this point. I wish I could talk to someone at Triumph so they could tell me what the heck is going on.

The next steps suggested by the shop are to find or fabricate a new reducer (since it seems that such a thing isn't available on its own, at least from Triumph -- it only comes already set into the handlebar), then find equivalent bolts to what were already in my bike (probably M4?) but with cap ends, which will go into the reducer which is still in the right side, and into the newly fabricated reducer on the left, and sit properly in the new adapters.

I have a friend who says he can fabricate the reducer, if I can find a bolt or rod with the right external thread to match the internal one of the bars -- he'd drill and tap it. I'd have to figure out exactly what kind of thread it needs.

I'm a bit concerned that the adapters won't be tight enough and will allow the mirrors to rotate around the axis of the handlebar.

I'm also not sure how to get a new reducer deep enough into the handlebar to be like the right hand side and then fixed in place -- if it's not fixed in place surely the smaller bolt can't securely attach to it.

And I'm now trying to figure out what the inside edge of the lockwasher is even supposed to be in contact with. The reducer is way too deep in the bar to make contact. I have a feeling that the remaining reducer (in the right side) is seated significantly deeper than it's supposed to be -- if it were more towards the "surface" it might be able to squeeze the washer.

This is all really frustrating.



It's the same on both kinds I have: 21mm outer diameter at the widest part.

 

If both your threaded inserts have now been removed( damaged). Install the correct fitting barend using an adapter, basically a long bolt with either a metal/rubber expansion sleeve.

Look to Rizoma for a solution.

 

Thank you both for the advice.

If both your threaded inserts have now been removed( damaged). Install the correct fitting barend using an adapter, basically a long bolt with either a metal/rubber expansion sleeve.

One side still has the reducer in it, and I think there probably wouldn't be enough depth before that for an expansion sleeve. I'd much rather remove the reducer in that side than have each side different from the other. So if I end up deciding to go the expanding thing route, how would you suggest removing the reducer? The shop said they tend to be welded in, though the one in the left just came out with the bolt, which it seemed to be sort of fused to.

 

Have you already tried tapping a bolt threaded into the insert? And by tapping I mean hammering If one side had a removable insert chances are the other one is not welded in. From memory, I think the expanding inserts are removed by loosening the bolt and tapping into the bar to collapse the expansion collar. Required some elbow grease with a ball peen on my factory bar ends but they did come out.

 

I don't think an expanding collar is involved at all -- the one in the left side (which came out all stuck together with the bolt and bar-end weight) was simply threaded on its outside to match the bar's internal thread.

 

Once you have removed the original inner fixing,and nolonger want anything to do with them.
The expanding adapters are simply a suggested option to put things back together again.

Those threaded inners are loctite in place, some more than others.
A proven method would be to back to screw out some,apply heat (hair dryer and not a heat gun or torch) then give the screw a friendly tap with a rubber mallet.

I used that very method when installing my Rizoma Retro mirrors/barends.

 

Those threaded inners are loctite in place, some more than others.
The correct method would be to back to screw out some,apply high heat (hair dryer and not a heat gun or torch) then give the screw a friendly tap with a rubber mallet.

Interesting, thanks!

So I have two options, it seems:

Option 1:

Fabricate a new reducer for the left side, to make it the same is the existing right side one. Find matching bolts with cap ends which will sit in the bar end adaptors. Potential problem: I don't think the lockwasher will be sandwiched; I think it'll be loose in there. Though I should probably double check the depth of the existing reducer and compare to how deeply the adaptor piece can get. Could be that I'm wrong and it'll be tight.

Option 2:

Remove the reducer in the right bar, and instead find bolts with expanding sleeves as 1Chaos suggested above. I'd have to shop around to find some which sit nicely in the adaptor parts.

 

Option 3.
Either remove or reinstall innerbar fixings.
Purchase Rizoma barends,that include everything you need to complete the install.

 

The mystery was mostly solved, all in one go today.

I went to a fastener shop to find equivalent bolts with a cap end, and also to look for a fat bolt to make reducers out of.

I handed over the smaller bolt. "First, I want a couple of exactly this, or as close as you have, in case I want to return the bike to stock. Then I want two with the same length and thread but with a cap end. Oh and can you confirm for me what thread this is -- would be good to know."

He takes it and tries it in a few metric thingies, and says "OK yeah, this is M5."

I said "wait, what? No, hang on, look at this thicker bolt" and handed it over, "I ordered this one specially from my bike dealer, and this one is definitely M5, so that smaller one can't be".

He takes the thicker bolt and tests that one too. "Nope, this one is M6. The smaller is M5."

So my dealer ordered specifically for me, by part number and while looking at the fiches the M5 bolts specified for this mirror kit and gave me M6 ones. I didn't realize -- took it mostly by faith and also by a naive test (they measure 5mm major diameter but I guess I'm bad at measuring?), and that one faulty bit of info really snowballed!

I picked up new M5 bolts both with countersunk heads (in case I go back to stock) and cap heads (which fit nicely in the adaptor parts). This of course means that I probably do have the correct adaptor parts. I also picked up an M16-2.0 bolt (this turned out to be the bars' internal thread), which a friend says he can turn into some new reducers.

I measured and found that the remaining reducer is too deep in the bar for the adaptor and lockwasher to make contact. So I think I'll pull this one out and put in two newly-fabricated ones, a little shallower so the lockwasher can do its job. I'll report back once I've made progress on that.

 

If memory still serves correctly.
The non-R versions use M5 and the R models use a M6 bolt.

 

Meanwhile I checked over my records and it turns out I misremembered which parts I reordered through my dealer. These bolts were not among them. So where I blamed my dealer above I should not have. Sorry, International!

I guess the lesson here is that I should definitively test parts as step 1.

The non-R versions use M5 and the R models use a M6 bolt.

The most likely explanation, then, is that the person I bought these mirrors from had the R and so that's why I had the wrong fittings for my bike.

 

Having said that, this fiche for the kit for Speed Triple R also specifies M5: Bar End Mirror Kit, Black Anodised - Triumph SPEED TRIPLE R (To VIN 735336) | Triumph SPEED TRIPLE R (To VIN 735336) Bar End Mirror Kit, Black Anodised supplied next day (UK only) by Fowlers Parts

Looks like they might have gone up to M6 in later years: Mirror, Bar End, Black - Triumph SPEED TRIPLE R (From VIN 735337) | Triumph SPEED TRIPLE R (From VIN 735337) Mirror, Bar End, Black supplied next day (UK only) by Fowlers Parts

It looks like the Street Triple R used M6.

Doesn't really matter any more though.

 

Doesn't really matter any more though.

Maybe not to you,May it serve as a reference for another poor sole reading,who could not install mirrors on his bike.

 

I had a '12 with similar difficulties. One side came out clean, the other side had an insert that came unglued, came out, and I never could get it to work. I ended up getting a Speed Triple R bar and replacing mine. I liked the black bar better anyway.

I sure did like the Triumph bar-end mirrors though.