Bicycle Mechanics - Breaking handlebars?

The sales clerk at my LBS told me today that one should replace handlebars every five years or so because the aluminum becomes fatigued and could break under the stress of riding. She winced when I told her that the Cinelli bars on my 18 year-old Trek racer were original equipment. We’re talking straightforward hook-style bars. By the way, I ride hard enough, but I am still on the light side (63 kilos/140 lbs).

Is this the truth, or did she just desperately need to sell me a new set of handlebars?

I went in to replace the bolt (the one leading down to the spreader in the forks) on my stem, which I broke while over-tightening it. It was original equipment, too. So, despite the bolt’s being cro-mo, she had a good argument going with the metal fatigue.

Cheers,
Jamie

Bars do break with no warning. The CTC did a poll and found that they usually break in France.
I had an idea of running a cable up through the bars, secured at the end plugs, may salvage enough control to enable you to brake.
Old fashioned bars with external central shim seems to be a much better design than unshimmed modern bars.

Originally posted by MichaelW
Bars do break with no warning. The CTC did a poll and found that they usually break in France.

I would have thought that they would break in half.

How much our-of-saddle climbing and bar-torquing do you do? I do replace handlebar stems after 10-12 years, for the same reason, and I do regularly inspect handlebars for minor cracks or imperfections which could lead to failure. Having broken two cranks while pedaling, I do worry somewhat about such things!

Incidentally, recumbent riders probably do not need to be as concerned about handlebar and stem stresses.

Aliminium does fatigue. I'd replace the bars, unless you really want to do a face-plant.

I'd say replace em. (speaking hypocriticly from behind the 30-year old Bellari's on my Gitane of course).

Seriously, tho- if you do more than cruise in this bike, its better to replace em.

Given the consistency of the “Replace em” answer, I shall do so. I did actually buy a new pair yesterday, but have not yet installed them. I ride reasonably aggressively. I have calmed down some from my racing days, but old habits die hard. I am not much of a sprinter, but I am a climber, in and out of the saddle.

I have a follow-up question for MichaelW. You mention “old fashioned bars with external central shim.” My original bars are Cinelli (18 years old). At the center of the bars (say the middle 6 inches or so), it is raised, or thicker, so that the handlebar tape is nice and flush with the raised part. Is this what you mean by “central shim” ?

The pair that I bought (Modolo) seems ever so slightly more flexible than the Cinelli. Could it be that the Cinelli is, despite its age, the better bar? I didn’t pay a lot for the Modolo (they were the best fitting which the store had, and I have little room in my budget).

Thanks for the advice.
Cheers,
Jamie

If budget is an issue, this is pointless. But there are some carbon bars out there today as well. I have no idea how they will stack up strength-wise, but some good names do offer them.

Since I am moving to France, should I bring a stock of extra bars with me? :o

Cheers...Gary

I've never had bars break, but I had a Cinelli stem crack across the top of the handlebar mount just behind the pinch bolt. Luckily it was very visible, so I replaced it as soon as I noticed.

A shim is any thin strip of soft metal which fills a gap. The shims on bars fill out the gap to the diameter of the stem clamp, and absorb any of the scoring that takes place at the clamp. Scoring in aluminium is a source of weakness.
Modern lightweight bars are butted to fit the clamp, but any scoring will affect the strength of the tubeing.

Modolo have a good reputation but can be very lightweight. Cinelli are still good, and 3TTT are good 'n cheap.

Carbon is a bit untested as bar material. It is best used for odd shapes (aerobars) but has little advantage for standard drops.

I'd definitely replace 'em. MBUK even has a 'Show us your broken bars' contest each month...

My bike has Answer Hyperlite bars (£75 / 150~ Grams). They had a couple of years of hard off roading and the bike has had 7-8 years in the garage since then - I am seriously considering replacing them :).