Can't rotate levers enough...how to resolve?

[Billyzoom]

Hey, folks.  I know I haven't done a proper introduction yet, but I'll do it soon...

my question is concerning the levers/throttle on my 07 s4rs...I wanted the bars rotated a bit more toward me, but when I did it and tried to move the levers more downward so my wrists felt natural, like I do to my mountain bikes, they would only move so far, even with everything loosened.  The throttle side was the problematic one...it would only rotate so much, which was not enought.  I couldn't fix it, so I put the bars and levers back as they were.  But it's not comfortable. 

Apparently there is some sort of pin or something to stop the rotation?  How can I get rid of it and then make sure everything can tighten up properly?  Appreciate your help.

Joel

[Duckintime]

The trottle grip has a pin that protrudes into a hole in the handle bar. Probably what is happening is the lever (brake) is hitting the housing for the throttle cable as it enters the throttle grip housing. About the only solution is to drill another hole in the bar, but dont go all the way through. If your bar is aluminum, drill enough just to put a good size dimple in the bar. Sand the locating pin on the throttle grip housing down a bit so as you clamp it all together, it squeezes the two halves of the housing shut. You bar has a hole already in it for that locating pin. If you drill another hole next to it, you can weaken the area and cause a crack between the two holes. This is why I would drill a dimple rather than a hole. Whatever you do, dont grind off the locating pin completely. That pin keeps the throttle grip housing from sliding off the handle bar.

[NoisyDante]

If you chose to you could grind the locking nub off completely with a small file.  It won't slip if  you put a little strip of electrical tape on the bar for the housing to bite into.

[Turf]

If you chose to you could grind the locking nub off completely with a small file.  It won't slip if  you put a little strip of electrical tape on the bar for the housing to bite into.

+1 lots of people have done it for various mods like switching handelbars or clip-ons.

[Billyzoom]

Cool.  Anyone have pics of specifically which bolts I have to undo to remove the throttle assembly and get at the nub?

[ScottRNelson]

Cool.  Anyone have pics of specifically which bolts I have to undo to remove the throttle assembly and get at the nub?

Two screws hold the throttle assembly in place.  Look underneath, you don't need instructions to find them.  Then just pay attention to where everything is when you open it up so you can put it all back in place later.

[corey]

Two screws hold the throttle assembly in place.  Look underneath, you don't need instructions to find them.  Then just pay attention to where everything is when you open it up so you can put it all back in place later.

It's a very easy thing to do.
HOWEVER, be very careful when reinstalling that you do NOT OVERTIGHTEN THESE TWO BOLTS. The throttle housing made of cheap pot-metal. If you overtighten it, it will break it in half. Get it pretty tight, then tighten it just a little bit further. Don't go all monster truck on it.

[NoisyDante]

Exactly, I cracked my throttle housing when I put my first set of bars back on it.  Luckily had a replacement piece from my old housing damaged in a crash, but it's definitely more fragile than you'd expect.

[Duckintime]

Seems most grind that pin off...hmm... dunno, for me i want that piece of mind that tape doesnt provide.

[mendoje]

+1

When I changed bars, I too ground off the pin on the LH controls and added a few wraps of tape.  Granted, it's just the lights, horn, etc, but I really didnt like the way it felt, not really secure. So on the RH side I took the trouble to locate and drill the holes.  Far more solid and secure.  Really wish I didnt grind that other pin now.  I'll reverse what I did somehow.

Seems most grind that pin off...hmm... dunno, for me i want that piece of mind that tape doesnt provide.