Bicycle Handlebar Plugs: Types, Tools, Safety, and Removal Guide

How to Remove Bicycle Handlebar Plugs?

Removing bicycle handlebar plugs typically involves understanding their retention mechanism—whether it's a simple friction fit, an expanding wedge, or integrated with bar tape—and then applying the appropriate tool and technique to safely extract them without damaging the handlebars or the plug itself.

Why Remove Handlebar Plugs?

Handlebar plugs, also known as bar ends or bar end caps, serve several critical functions, including securing handlebar tape, protecting the ends of the handlebars from damage, and preventing injuries in the event of a crash by covering sharp tube edges. Reasons for removal often include replacing worn handlebar tape, upgrading to new plugs, performing maintenance on internal components (e.g., internal cable routing), or accessing the handlebar interior for accessories like mirrors or lights.

Tools You'll Need

Having the right tools ensures a smooth and damage-free removal process.

• Small Flathead Screwdriver: Essential for prying and manipulating plastic plugs.
• Hex Key (Allen Wrench) Set: Specifically a 4mm, 5mm, or 6mm key for expanding-type plugs.
• Pliers (Needle-nose or standard): Useful for gripping stubborn plugs or components.
• Utility Knife or Scissors: For cutting old bar tape, if necessary.
• Heat Gun or Hair Dryer (Optional): For softening adhesive or stubborn plastic.
• Protective Eyewear: Always recommended when working with tools.
• Work Gloves: To improve grip and protect hands.

Safety First

Before beginning, always prioritize safety to prevent injury and damage to your bicycle.

• Secure the Bicycle: Ensure your bike is stable, ideally in a repair stand, to prevent it from moving or falling during the process.
• Assess the Plug Type: Visually inspect the plug to determine its retention mechanism. This will dictate the removal method.
• Apply Gentle Force: Avoid excessive force, which can strip screws, break plastic components, or scratch your handlebars.
• Protect Your Eyes: Small pieces of plastic or metal can become dislodged.

Step-by-Step Removal Guide

The removal method depends heavily on the type of handlebar plug installed.

1. Standard Friction-Fit Plastic Plugs:

• Identify: These are the most common and often come with new bikes or handlebar tape. They are typically pushed directly into the handlebar end.
• Method:
  • Pry Gently: Use a small flathead screwdriver. Insert the tip into the gap between the plug and the handlebar.
  • Leverage: Gently twist the screwdriver or lever it outwards. Work your way around the plug, prying it little by little from different sides.
  • Wiggle and Pull: Once loosened, you can usually wiggle the plug free with your fingers or a pair of pliers. Avoid pulling too hard on one side, which can bend or break the plug.

2. Expanding-Type Plugs (Bolt-Secured):

• Identify: These plugs have an internal bolt that, when tightened, expands a rubber or plastic sleeve, creating a secure fit within the handlebar. They are commonly found on higher-end bikes or aftermarket setups. You'll see a hex bolt head in the center of the plug.
• Method:
  • Loosen the Bolt: Insert the correct size hex key (typically 4mm, 5mm, or 6mm) into the center bolt of the plug.
  • Counter-Clockwise Rotation: Turn the hex key counter-clockwise to loosen the bolt. You will feel the tension release as the expanding mechanism retracts.
  • Pull Out: Once loosened sufficiently, the plug should slide out easily. If it's still snug, gently wiggle it while pulling. Do not force it, as the internal mechanism may still be expanded. Continue loosening the bolt if resistance persists.

3. Plugs Integrated with Bar Tape:

• Identify: Some handlebar tape kits include plugs that are designed to tuck the end of the tape into the handlebar, with the plug holding both the tape and itself in place.
• Method:
  • Unwrap Tape (if necessary): If the tape is old or you plan to replace it, you might need to unwrap the last few inches of the handlebar tape near the plug to expose the plug's edges.
  • Access the Plug: Once the tape is out of the way, treat the plug as either a standard friction-fit or an expanding type, depending on its design, and follow the corresponding removal steps above.
  • Note: If the tape is adhered strongly, a utility knife may be needed to carefully cut the tape away from the plug's edge.

4. Stubborn or Stuck Plugs:

• Heat Application: For very old or tightly stuck plastic plugs, a heat gun or hair dryer on a low setting can gently warm the plastic, making it more pliable and easier to remove. Apply heat briefly and evenly, being careful not to melt the plastic or damage the handlebar.
• Lubricant ( sparingly): A tiny amount of penetrating oil or WD-40 can sometimes help, but use with extreme caution to avoid getting it on brake levers or grips, which could compromise safety. Apply only to the very edge of the plug.
• Leverage with Care: If a plug is truly stuck, you may need to use more leverage with a flathead screwdriver or pliers, but always be mindful of not damaging the handlebar itself.

Troubleshooting Common Issues

• Stripped Hex Bolt: If the hex bolt head on an expanding plug becomes stripped, you may need to use a screw extractor kit or, as a last resort, carefully drill out the center of the bolt (this should only be attempted by experienced individuals or a professional).
• Broken Plastic Plug: If a friction-fit plug breaks during removal, you might be left with pieces inside the handlebar. Use needle-nose pliers or a pick tool to carefully extract any remaining fragments.
• Damaged Handlebar: If the handlebar opening is damaged during removal (e.g., bent or scratched), assess the extent of the damage. Minor cosmetic scratches are usually fine, but significant deformation could compromise the handlebar's integrity.

Proper Re-installation

Once the old plugs are removed, ensure the handlebar ends are clean and free of debris before installing new plugs or re-wrapping your handlebar tape. Proper re-installation is crucial for safety and longevity.

When to Seek Professional Help

If you encounter significant difficulty, are unable to remove a plug without risking damage, or if a plug's internal mechanism is broken, it's always best to consult with a professional bicycle mechanic. They have specialized tools and expertise to handle even the most stubborn cases safely.

Conclusion

Removing bicycle handlebar plugs is a straightforward task when approached with the correct tools and techniques. By identifying the plug type and applying the appropriate method, you can safely and efficiently remove them, paving the way for maintenance, upgrades, or simple aesthetic changes to your bicycle. Always prioritize safety and exercise patience to avoid damaging your equipment.