So today I finished installing a new Gafler braided brake line on my 03 Volusia. I've had the bike for 8 years now and I know I've never changed it, so quite possibly the original 16 year old line. I had flushed and replaced the fluid since I've had it, but still the original line.
In the process of wrestling the bike around to position the master cylinder to expedite the fluid flush and refill, I noticed my handlebars were a little looser than normal. I've had to tighten them before, so nothing surprising. Get the appropriate socket and ratchet, make a few turns on the bottom of the left riser. Make a few more turns, and a few more turns.... uh, it won't tighten up. OK, move to the bottom of the right side, tightens up fine. I'm walking back around the front of the bike to try and tighten the left riser thinking it was really strange how it must have backed out that far, when I hear the bolt and associated washers fall out and hit the ground.
UH, OH.... not loose, but stripped out. Appears to me, whoever installed the risers, used a bolt that was not near long enough. Only about 1/2 inch of that bolt was threaded in the bottom of the riser. I've had the bike 8 years and never had a reason to mess with the bars as it fits me perfect.
I can only imagine what could have happened if that bolt had decided to turn loose on a mountain road, or any road for that matter. Dodged a bullet.
So, not going to mess with trying to tap the old riser. They're cheap enough to just replace. And you better believe, I'll have a longer bolt installed.