Go Back  Bike Forums > Bike Forums > Classic & Vintage
Reload this Page >

25.4 Sakae handlebar won't fit into 25.4 stem

Classic & Vintage This forum is to discuss the many aspects of classic and vintage bicycles, including musclebikes, lightweights, middleweights, hi-wheelers, bone-shakers, safety bikes and much more.

25.4 Sakae handlebar won't fit into 25.4 stem

Old 05-19-13, 05:36 PM
Junior Member
Thread Starter
Join Date: Apr 2012
Posts: 15
Likes: 0
Liked 0 Times in 0 Posts
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 :-).
koko236 is offline  
Old 05-19-13, 06:18 PM
Senior Member
Join Date: Apr 2006
Posts: 3,652
Likes: 0
Liked 107 Times in 80 Posts
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
rhenning is offline  
Old 05-19-13, 07:08 PM
Join Date: Nov 2010
Location: South of the North country
Posts: 194

Bikes: Various home-built frankenbikes

Liked 37 Times in 23 Posts
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...
1987 Nishiki Prestige (now 650B!)
1981 Trek 710
198? Nishiki Olympic 12 mixte (now 650B!)
2020 Surly Troll fat-tire build

ctmullins is offline  
Old 05-19-13, 07:17 PM
Junior Member
Thread Starter
Join Date: Apr 2012
Posts: 15
Likes: 0
Liked 0 Times in 0 Posts
The stem is aluminium not steel, is it ok to spread it like that?

Baking sounds good, might try it with tires as well..
koko236 is offline  
Related Topics
Thread Starter
Last Post
Bicycle Mechanics
06-19-17 12:36 AM
Bicycle Mechanics
09-21-16 06:45 PM
Classic & Vintage
07-19-14 09:10 PM
Singlespeed & Fixed Gear
01-24-11 08:07 PM
Singlespeed & Fixed Gear
01-08-10 08:20 AM

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

Thread Tools
Search this Thread

Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service - Your Privacy Choices -

Copyright © 2024 MH Sub I, LLC dba Internet Brands. All rights reserved. Use of this site indicates your consent to the Terms of Use.