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25.4 Sakae handlebar won't fit into 25.4 stem

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25.4 Sakae handlebar won't fit into 25.4 stem

Old 05-19-13, 05:36 PM
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25.4 Sakae handlebar won't fit into 25.4 stem

Hello everyone,

it's the first time I couldn't find existing answer to my problem on this forum :-)

I recently bought Sakae World Custom Super Light drop handlebars (with a double tube in the middle rather than a typical bulge) which should be in 25.4mm size in clamp area but wont fit an ITM stem in the same size. At first I thought I got two different standards mixed up but it doesn't look so.

The stem used to hold another Sakae in 25.4mm standard but its' inner diameter looks more like 25.25mm to me and it was a bit tight on the bar. The new Sakae measures 25.55mm on my calipers and the old one was more like 25.3 mm which I guess is the only proper dimension here...

Now the question is what are my options apart from ditching one of the parts? Is it safe to try to bend the stem outward the missing 0.3 mm or should I widen the stem hole with sandpaper or dremel tool? Is it safe to mess with a stem like that? How often do such misalignments happen? 0.3mm seems like a lot off considering 0.2mm is the difference between ISO and french stem diameter and is enough to make you drill the wrong stem out of the fork (it was enough for me that is :-).
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Old 05-19-13, 06:18 PM
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Take the bolt out. Put a wedge in the stem bolt area and spread it until you can get the handle bars in the right place. A large screwdrive end will usually work. Put the bolt back in and tighten. Roger
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Old 05-19-13, 07:08 PM
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Or, you could do as I once did, long ago, before I had nearly the wisdom I have now: I had a 25.4 stem and a 26.0 bar; I baked the stem in the oven at 350 for 30 minutes (or until the stem just begins to brown). Works great, but isn't exactly reversible...
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Old 05-19-13, 07:17 PM
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The stem is aluminium not steel, is it ok to spread it like that?

Baking sounds good, might try it with tires as well..
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