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Bar end shifter too big for inside diameter of handlebar

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Bar end shifter too big for inside diameter of handlebar

Old 02-21-21, 03:58 PM
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RichinSC1
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Bar end shifter too big for inside diameter of handlebar

I am installing bar end shifters into my handlebar but the width of the shifter is 1mm larger than the open end of the handle bar. Is there a way to expand the handlebar opening either by brute force or heat?
The width of the shifter is 19mm and the inside diameter of the handle bar at the end is 18mm. Thanks for your reply
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Old 02-21-21, 05:11 PM
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Originally Posted by RichinSC1 View Post
I am installing bar end shifters into my handlebar but the width of the shifter is 1mm larger than the open end of the handle bar. Is there a way to expand the handlebar opening either by brute force or heat?
No, that's vastly too big of a diameter discrepancy.

The width of the shifter is 19mm and the inside diameter of the handle bar at the end is 18mm. Thanks for your reply
That's an unusually narrow bore for a road drop handlebar.

What type of handlebar is this? What is the outside diameter of the handlebar tubing (most likely either 23.8mm or 22.2mm)?
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Old 02-21-21, 06:17 PM
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Just buy new handlebars with the correct internal sizing needed to fit your bar end shifters.

Curious what brand and model bars you have.
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Old 02-21-21, 06:24 PM
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I have bull horn handlebars and I'm having a hard time finding any new ones that have a larger inside diameter.
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Old 02-21-21, 08:54 PM
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Originally Posted by RichinSC1 View Post
I have bull horn handlebars and I'm having a hard time finding any new ones that have a larger inside diameter.
What is the outside diameter of the handlebars? Not at the stem clamp, but where you'd grip them.
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Old 02-21-21, 09:04 PM
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Originally Posted by HTupolev View Post
What is the outside diameter of the handlebars? Not at the stem clamp, but where you'd grip them.
21mm OD at the bar end.
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Old 02-21-21, 09:27 PM
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Originally Posted by RichinSC1 View Post
21mm OD at the bar end.
That's probably the source of your trouble.

In the industry today, there are two main standards for the handlebar outer diameter. MTB handlebars typically use 22.2mm, road handlebars typically use 23.8mm. There aren't really any firm standards on inner diameter, but 23.8mm "road" handlebar tubing usually has an inner diameter of around 19.5mm or wider. That's what the expanders on bar-end shifters are usually designed to pair with.

If your bullhorns are designed more to MTB spec, then this explains why the inner diameter is too narrow for the bar-end shifters.

This unfortunately puts you in a complicated position. The obvious solution is to look for bullhorns with a 23.8mm outer diameter, as these are pretty likely to play nicely with bar-end shifters. The drawback is that, if you already own brake levers that clamp nicely on your narrow-outer-diameter handlebar, their clamps might not fit properly on a 23.8mm bar, which would be another thing that needs to be sorted out.
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Old 02-22-21, 07:16 AM
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I've used an adjustable reamer shave a little off the inside. You can buy one at tool stores.
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Old 02-22-21, 08:47 AM
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Can you take a file to your shifters to thin them out some?
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Old 02-22-21, 09:01 AM
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Originally Posted by topflightpro View Post
Can you take a file to your shifters to thin them out some?
Can not file shifter but MAYBE can file ID of handlebar.
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Old 02-22-21, 09:36 AM
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Originally Posted by RichinSC1 View Post
Can not file shifter but MAYBE can file ID of handlebar.
I've done it a few times. That's why I bought an adjustable reamer.
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