Bicycle handlebars are connected to the wheel with a series of components. The stem attaches the handlebars to the headset, which attaches to the fork tube, which attaches to the wheel. Stuck bicycle handlebars are a common maintenance problem and normally caused by corrosion. Corrosion occurs when steel and aluminum components are housed together. In the presence of moisture, these two metals oxidize and bond over time. Freeing the handlebars requires breaking this bond.
Boiling Water
Because aluminum is less dense than steel, it heats up and cools down quicker. If you have a metal handlebar stem that is stuck in an aluminum frame, you can use boiling water to help free it. Lay your bike down outside and pour a large pot of boiling water over the handlebar stem, where it connects to the frame. The aluminum will heat up and expand quicker than the steel, but it will also shrink faster. After several hours, when the bike has cooled, try to remove the handlebars. The expansion and shrinking of the metals should have broken the corrosive bond.
Ammonia
Ammonia is a highly caustic acid that is effective at dissolving the corrosive bond between aluminum and steel. Put your bike in a well-ventilated area and, if possible, soak the handlebar and connections in a large container of ammonia. If you cannot soak the handlebars, pour ammonia over the stuck components regularly throughout the day. After several doses, rinse the handlebars in water, dry and attempt to pull the stuck components free.
Pound Out
If a handlebar is not freed by heat or chemicals, you may have to use physical force. Start by removing the wedge or expander bolt that holds the handlebars in place. This is located at the bottom of the fork tube, where the bicycle fork attaches to the frame. Most wedges or expanders are held on by a 6-mm Allen bolt. Loosen the bolt and remove the wedge, then insert a long screwdriver or thin steel tube up into the fork tube. Use a hammer to pound up, through the tube and against the handlebars until they break free. You may want to tape off the fork and frame to prevent chipping from errant hammer strikes.
Prevention
Keep your bike handlebars from getting stuck with proper prevention techniques. Wipe your bike off after rainy rides and always store your bike inside or under a cover. Water is the main cause of corrosion and stuck handlebars. Regularly grease your handlebars, stem and headset components to help keep out moisture and maintain movement. Wash your bike every few months to get rid of dirt and dust that can dry out grease and cause handlebars to stick.
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