New handlebars - Throttle housing loose

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drones76

drones76

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Bought a new set of handlebars, they were the proper height, pullback etc and they are an exact match for the former ones except the new ones were not bent. :) The issue is that the throttle twist housing does not clamp down on the bars completely. They are loose enough to slide off. The switch clusters tighten up just fine. I am assuming the bars are a bit smaller in diameter that the originals. Looking for suggestions to fill the gap. As a temp solution, I had put a piece of duct tape around the bars at the clamping point. Worked well until it got hot out.
 
Had the same problem.
I bought a grommet kit and fit the properly ID sized grommet over the bars.
I then fit the switch housing edge into the exterior slot on the grommet to compensate for the extra spacing.
Snugged the switch housing up carefully, no more slop or slippage.
 
drones76 said:
Bought a new set of handlebars, they were the proper height, pullback etc and they are an exact match for the former ones except the new ones were not bent. :) The issue is that the throttle twist housing does not clamp down on the bars completely. They are loose enough to slide off. The switch clusters tighten up just fine. I am assuming the bars are a bit smaller in diameter that the originals. Looking for suggestions to fill the gap. As a temp solution, I had put a piece of duct tape around the bars at the clamping point. Worked well until it got hot out.
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You can sometimes get away with carefully sanding the housing on a surface plate, doing both pieces equally.
 
happens often 22mm bars made in China as opposed to being made with correct diameter 7/8" tube (22.2mm)
 
I have the same problem on the MK 111 , right throttle side.
Tape is not the answer.
Surface plate sanding down is a one way street but it's summer and I want to ride so more temporary tape. Considering a zip tie to increase clamping pressure tomorrow.
 
More importantly make sure the handlebar clamps can properly clamp the bars securely. There should be a gap between the clamps and top yoke after fully tightening.

Cheers,

cliffa.
 
I found a less elegant solution. I cut the pinky off of a thicker nitrile glove and then cut it into two rings about 1/2 inch thick. And then put them over the bar at the point where I needed additional contact. Screwed down the throttle housing and it seems to be holding got to give it a test ride today. At least there's no glue to melt in the heat now.
 
I wrapped some aluminum foil tape around the handle bars to make it a bit thicker.
 
Some brilliantly innovative solutions posted here.

All triggered by incorrect, sub standard pattern parts!

Hopefully will make some reflect that it is really worth paying a few $ more for correct parts, not only will they fit and function correctly and safely, they’ll also save you time and headaches.

If we all buy shit, then that’s all we’ll be sold in time.

Support the good vendors guys, for all our sakes !
 
Wrap a narrow strip of fine wet or dry around the handlebars where the throttle clamps on. Abrasive surface towards the handlebar. Do not overlap. Slide throttle over the wet or dry and tighten. BTW I had to do this after buying bars from one of this forum's most beloved suppliers. Even the best supplier can't be on top of everything.
 
When I asked this same question here back in January, the answer I recieved was to use beer can alu strip to wrap around bar to get better clamping force. For my bars, it was the Switchgear that were loose.
 
I had the same problem with a new set of Euro bars sourced from a most beloved manufacturer/vender.
Using an empty aluminum beer (ale) can I cut a strip the exact size to act as a shim. Has worked perfectly.
 
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