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I have an extremely nooby question, please bear with me. I was trying to swap out my handlebars today and I'm having trouble getting my throttle housing off. It seems like it should be an easy thing, removed two phillips on the bottom, the top part of the housing comes off but the bottom part is really stuck on there. I don't see anymore screws I could remove.
From all the vids I've seen, other ppl's throttle seems to slide right off after removing the screws. The only thing I could think of is disconnecting the throttle cables. I kinda tried but it doesn't seem like I have enough slack to disconnect the cables from there. I didn't have much time to experiment since it started to rain and I had to stop.
Would I have to disconnect my throttle cables?? Or is there something that I'm just not doing right?
Here's a pic.
Oh and since I'm already here asking stupid questions. I was wondering if anyone tried to use soapy water to install their grips? I only have experience in bicycle wrenching. And soapy water was a legitimate way of installing grips since it helps slide the grips on and when it dry, the stickiness allows the rubber to stay in place. Does that sound like it would work or should i run out and get some grip glue?
There should be a lock nut underneath for your cable housing. The end of your cable should go into a metal tube and make a 90* bend before entering the housing itself. Loosen up that lock nut, unscrew the cable tube, this will give you enough slack to take the throttle cable out. Once that's off, you should be able to slide the tube straight off, but if not, coax it with LIGHT taps from a small hammer, preferably rubber or plastic if you have one. Take your time, and tap it gently, and it should unstick from the bars.
On the question about the grips. Soapy water works fine, it won't damage anything and once it dries will make your grips stick to the throttle tube and to the bar itself on the left side. Good luck
I tried wiggling the bottom of the housing. It does have a bit of play, which is why I assume it'ld just slide off but it won'd budge. I thought there might be a pin in there that goes into a tiny hole in the bars for stability but that wouldn't explain the play. I'll try disconnecting the cables and taking a rubber mallet to it.
It's pouring in nyc now, i can't go out to work on it :'(
If you have play in the lower housing, and the throttle tube moves freely (in a twisting motion, like reving the bike) the assembly should slide right off as there's nothing else to "stick". Most likely there is a locator pin in the lower housing that's hanging it up.
Try and peek into the bar end with a light, you should be able to see if there's a locator pin. Or atleast see the dimple/hole in the bar where the pin sits. There should be no need for a rubber mallet. Once you loosen/remove the cables, you should be able to put enough gentle downward pressure on the lower part of the housing to remove it from the bar.
You might have to loosen off one of the cables at the carb end to get enough slack to remove the cables from the throttle grip tube. Or if you're replacing your bars, undo the bars and slide the complete assembly off the end.
I've found grips are best put on dry with compressed air. Soapy water, solvents, etc will leave some residue in there which can become slippery again (especially if you ride in the rain). Or a little spray of brake cleaner should give you enough lube to slip them on before it dries out.
It finally stopped raining this evening so I retried disconnecting the cables. I loosened the nuts on the 90degree cable tube. However, there is still not enough slack for me to unscrew the 90degree cable tube from the throttle housing. I tried squeezing in a flathead screwdriver under the cable but it just won't pop off.
I'm afraid I might have to loosen the cable from the carb end. Sigh. Damn street parking plus 9-7 job makes me not have enough time in a day to work on it. It's alternative parking tmrw too and my bike is on the wrong side of the street. Lesson of the day: While street parking, never attempt to work on your bike while it's parked in first gear.
Btw, where is the front rubber attachment of the fuel tank located? I loosened the rubber that ties the tank to the front of the seat. None of the manuals I have goes into much details other than "remove ur fuel tank". I can feel there's another attachment in the front somewhere but I can't see it.
I can't quite tell from the pics, but if some of wiring goes THROUGH the handle bars that could be what's stopping it from coming out\off. IF so, you'll need to unplug them to pull off the housing anyway. Mark the wire or number them, it helps to twist them slightly if they're held up in the bars, I've had a few that were pretty well melted it the bars.
^^^ it does.
But I don't think it's the wires right now that's causing the throttle assembly to stick so tightly to the bars, coz the left hand controls also have wires running thru the internal bars and i managed to get it off.
I think i got it. Finally found a manual with handlebar disassembly. "Disconnect the throttle cables A and B from the carburetor throttle cable stay." I'll try that again. Hopefully 3rd time's the charm.
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