Gen 1: As of March 20th, 2020 we have 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 us and most likely the oldest performance part on your bike. If you're interested in upgrading to our current Generation 4 bar, shoot us a call or email, we're happy to help. 877.306.1801 / Ridersupport@fasstco.com
Here is an example of Gen 1 Bar grid:
Gen 2: The Gen 2 was made from January 2010 to March 2014.
Here is an example of a Gen 2 Bar grid, the biggest indicator being"With FB Technology":
Gen 3: The Gen 3 bar was made from April 2014 through July of 2022.
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":
1. Ship us the bar and we'll service it for you.
2. Service it yourself.
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.
How to service your Flexx Handlebars
Factory Fresh Service
We also offer our free Factory Fresh in-house service program for your Flexx Handlebars. This service requires you obtain an RA# from us. Next ship us your bars with the RA# and signed release form, Attn: Factory Fresh. The Factory Fresh service program for Flexx Handlebars is free with the purchase of a Service Kit. The Factory Fresh program consists of disassembling and cleaning your Flexx Handlebars, a thorough servicing of the pivots and reassembly with a Flexx Handlebar Service Kit. The Service Kit consists of new o-rings, clips, bolts, washers, and nuts as well the compression and rebound elastomers, as well as our proprietary fiber pivot bushings for Gen 2 and 3 riders. Please note that this is only a clean and lube job, in no way does this make your handlebar stronger, last longer or take away any prior damage/neglect. If your Flexx Handlebar is damaged in anyway we will inform you of the damage and what your options are. We will not return damaged handlebars to you as it is a safety concern and liability to yourself.
Proper Handle Resistance
Your handles may have some drag or resistance when the elastomer is removed. The drag is caused by the exacting tolerance required for the Flexx Handlebar to offer the utmost in control and reliability. Flexx Handlebar pivot points are most likely the most exacting tolerance on your entire machine and must be so. Too large of a tolerance will not the yield the precise control you as a rider require to perform at your best. It is not only acceptable but preferred to have some drag on the handles. Each side of every Flexx Handlebar System is measured with a strain gauge to be sure the resistance of each handle is within our tolerance. If your bar rebounds to its present ride height after being compressed you should be good to go. If you have any questions concerning this please contact us. *If your pivot pins are damaged they will need to be replaced. A Pivot Pin kit is an additional $20. Download theService Order Form
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.
12 or 13mm wrench
hammer or press (air hammer is preferred, but not required)
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.