Description
REBUILD, RENEW, AND RIDE. FULLY REBUILD YOUR FLEXX HANDLEBARS TO FEEL LIKE NEW.
Compression Elastomer Color Break Down:Â
(#1) Red – Hard
(#2) Yellow – Medium
(#3) Blue – Soft
(#4) Green – VERY Soft, great in our Low Bar and Mini Bends.
Rebound Elastomer Color Break Down:
(#1) Red – Hard
(#2) Yellow – Medium
SETUP TIPS
- Most Common Setup – Everyone is a little different with what they want out of the Flexx Bar. Most riders prefer yellow compression elastomers with red rebounds. If you’re trying to minimize as much vibration as possible you’ll likely end up on a blue compression elastomer and yellow rebound with the elastomer nut backed off to the 2nd or 3rd thread.
- OE Adjustments – FasstCo. ships the bar with red compression elastomers and red rebound elastomers. The stock setting on the nut is 3 threads showing past the nut. This set up is on the stiffer side of what the bar is capable of.
- Fine Tuning Tips – Each elastomer is tunable on it’s own by going in or out with the nut. You can run the elastomer nut anywhere from the 2nd thread to the 5th thread. If you go in on the nut it will stiffen the bars, going out will make the bar more compliant, we consider this the fine tuning between elastomers.
- Compression And Rebound – We can’t stress this one enough. Please be sure you’re not running two compression elastomers on each side. You should be running a thicker compression elastomer on the inside and a thinner rebound elastomer on the outside. If you’re running two compression elastomers the bar will be substantially stiffer than they should and not an accurate depiction of what the Flexx Handlebar is capable of.
What’s in the box:
- The Gen 1 Factory Fresh Kit – DISCONTINUED
- The Gen 2 Factory Fresh Kit – contains 4 c-clips, 16 o-rings, two bolts, two nuts, two washers, your choice of Rebound and Compression Elastomers, 2 handle Fasst bushings and 4 center section Fasst bushings. LIMITED GEN 2 KITS AVAILABLE, DISCONTINUING DECEMBER 2023.
- The Gen 3 Factory Fresh Kit – contains 4 c-clips, 16 o-rings, two bolts, two nuts, two washers, your choice of Rebound and Compression Elastomers, 2 handle Fasst bushings and 4 center section Fasst bushings.
- The Gen 4 Factory Fresh Kit – contains 4 c-clips, 16 o-rings, two bolts, two nuts, two washers, your choice of Rebound and Compression Elastomers, 2 handle Fasst bushings and 4 center section Fasst bushings.
Gen 1: As of March 20th, 2020 Fasst Company discontinued all Generation 1 Factory Fresh Kits and replacement parts. The gen 1 bar was manufactured from January 2002 through December 2009, if you’re still on a generation 1 bar it’s a minimum of 14 years old. A testament to the American Made quality you’ve come to expect from FasstCo. and most likely the oldest performance part on your bike. If you’re interested in upgrading to the current Generation 4 bar, shoot us a call or email.
Here is an example of Gen 1 Bar grid:
Gen 2: The Gen 2 was made from January 2010 to March 2014.Â
Here is an example of a Gen 2 Bar grid, the biggest indicator being “With FB Technology”
Gen 3:Â The Gen 3Â bar was made from April 2014 through July of 2022.Â
Here is an example of a Gen 3 Bar grid, the biggest indicator being “With FB3 Technology”:
Gen 4: The Gen 4 bar is our current bar, we made the switch to the Gen 4 in August 2022. The notable difference from gen 3 to gen 4 is the length of the crossbars. For Gen 4 we went to one standard crossbar length. Our atv, enduro, moto, and adventure bars will use SHORT CROSSBARS ONLY.
Here is an example of a Gen 4 Bar grid, the biggest indicator being “With FB4 Technology”:
THE STEP BY STEP SERVICE PROCESS
TWO KEY THINGS TO REMEMBER
1) Do not mix the pivot pins up. The left pin needs to go back in the left hole, and the right pin in the right hole. We separate our pins and hone our pivot holes to .0001 of an inch. It is crucial to have proper fitment of each pin so there is not front to back play. 2) The second key point is do not strike the pivot pin directly with a hammer, press or any other form of tool. A dowel or punch must be used to protect the pivot pin from “mushrooming”. If you do not have a proper dowel or punch to match the pivot pin diameter you can use an old bolt to protect the pin.
TOOLS REQUIRED
- 12 or 13mm wrench
- 6mm allen
- c-clip pliers
- punch
- hammer or press (air hammer is preferred, but not required)
- safety glasses
Servicing your Flexx Handlebar can be done on or off the machine. It is easier to do off the machine if you have a proper vise. Be sure if you do place the Flexx Handlebar in a vise you use plastic jaws or a similar product to protect the Flexx Handlebar from being damaged by the jaws. It is also important to note that whenever working with c-clips that proper safety eyewear is worn. C-clips have a tendency to fly off at warp speed when being removed or installed and although we know you want your Flexx Handlebar to perform as it is intended to it is not worth losing an eye over!
- Remove the elastomer nuts, slide the bolts back, then remove the elastomers.
- Remove the rear c-clips and rear crossbar.
- Tap the pivot pins forward slightly which allows easier access to the front c-clips. Remember not to strike the pivot pins directly.
- Remove the front c-clips and front crossbar.
- Now drive the pins completely out. Again, be sure not to strike or press on the pivot pin directly. Do not mix the pins up.
- Clean pivot holes and pivot pins. Remove the old o-rings and replace with new ones.
- Lube the pivot pins as well as pivot holes with anti-seize.
- Place the pivot pin in the back side of the bar, square to the bore. You will know the pin is square to the bore when it will not rock easily up, down, or to the side without applying force.
- Now tap the pivot pin all the way through the handle out the other side. It is easiest to replace the c-clips if the pin is extended out slightly past the crossbar.
- Place one o-ring on the front, outside of each pin, and then place the crossbars on to the pins. The extra 0-ring will keep the crossbars from vibrating. You may need to place an extra o-ring on the back side as well.
- Install the front crossbar and c-clips. Carefully tap the pins back until the c-clip is against the crossbar.
- Install the rear crossbar and clips. Be sure all of the clips are securely in their designated groove by pulling the crossbars away from each other.
- Install nuts, bolts and elastomers.
Additional information
Weight | 2 lbs |
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