trying to install the sv650 handle bars

[MountainDew]

I am installing the Suzuki 650 type 2 handle bars on my bake and I got everything off and I have the new handle bars on but now the throtter body and the other sided boxs don't fit on the bars dose anyone know how to fit this???

[pantablo]

how do they not fit? Are you having trouble getting the little nub on the inside of the throttle body (and clutch side switchgear) to meet the hole in the SV bars? You might have them upside down (not sure if it matters though).

pablo-

[MountainDew]

never mind Im stupid as heck!! I wasn't line up the hole and the tab. But Im still haveing trouble with the cluch leaver, When I was tighting up the cluch I started getting little bit of metal around the screw and now it won't tighen up? Im not sure if I striped it or what but it seem like everything Iv'e taken off has gave me problems!!!

[Anonymous]

You stripped it, it most likely will never tighten...

[Stephen072774]

mine took quite a bit of adjustment before I got the levers and mirrors just right.  Ended up with the bar pretty much flat on the triple and the tops of the bar were under the gauge ring.

[MountainDew]

I got the breaks the best I feel I can do but there still a gap inbetween the break and throtter body which I guess I have to get use to it. The screw in the cluch leaver is still not tighting up, is there a tick to screwing in it?? Also I got new grips for my bars because I had to cut them off and the new ones are pretty lose is that how they should be or are they to big??

[stephan]

Yeah, replacing the bar can be tedious.  I wrecked my "pull clutch to start" switch.  Had to do some *ahem* creative electrical work!

:mrgreen:

[cajrovd]

Don't take my word for it, and this might be the last resort, but you could try using a screw that's the next size up (width, not length).

My throttle body and brake lever assembly didn't fit as tightly together as the stock bar did either. But as long as the throttle isn't sticking out the end of the handlebar and you can fit the bar end on, then its ok.

[MountainDew]

well after looking at it for afew minutes I found out that where the screw thread in is striped at the last few threads so Im thinking about rethreading it, would the suzuki dealership be able to do it?? Also is there a trick to putting the grips on because I was trying to put the lift one is and it was really hard to put on?? one more thing. The holes on the bar that your supost to line the throttle body and cluch body onto, well I could line the lift (cluch body) onto the hole but the throttle body won't line up because of the the thing you fill the break fluid in. so Im thinking about filling that hole in what would you guys use to fill it in with??

[cajrovd]

Getting the left grip on - use soapy water - Pablo's suggestion

The brake assembly will have to be tilted forward (so that it can slide over enough under the guage) to get the throttle body to line up. It should line up. I would try and get the throttle body lined up so that the little piece of plastic goes into the hole, it will help prevent the throttle body from rotating when twisting the throttle.

[MountainDew]

Alright, well I had to do a half @$$ job because I wanted to ride it alittle befor winter. It looks like this well be my winter project now.

The list of stuff to do!!
new cluch
new throttle body (because I cut the little pice of plastic)
fill the stock throttle body hole in and drill new one
paint bar stock black

What would you use to fill in the hole with? I was thinking ether bondow (Im pretty sure I didn't spell that right) or should I get someone to weld the hole closed??

[MountainDew]

Alright this might be a stupid question but the dealership said they replace any part on my bike if it broke within the frist year I have my bike so would they replace the cluch leave? It striped when I was tightening it up, Im not sure if it was my fault or suzuki.

[pantablo]

It striped when I was tightening it up, Im not sure if it was my fault or suzuki.

That would be your fault.

Unlikely dealer will replace parts damaged by you. More likely parts that fail on their own (and thus are Suzuki's fault) will be replaced.

[MountainDew]

Yeah I was just hopeing that they wouldd but I know it wasn't going happen