need handlebar replacement help

[matthewlanglois2984]

Hey. I just replaced the stock handlebars with some drag bars and am having trouble fitting on the two switch assys at each end. The 2 handlebars are the same size but when trying to bolt the switch assys on theres a seperation and they wont fit properly ? tried just about everything...when i try to tighten to fit it doesnt seem to work cause the throttle sticks. if anyone has advice or knows how to fit them on please lemme know im not quite sure what to do. Thanks!

[davipu]

ok, if I remember right , the wires on the throttle side (inside) have to be on the side of the bars to the rear, otherwise they will pull tight and you won't get them to screw down all the way, the throttle sticking could be either the plastic sleeve isn't in the grouve whare it's soupposed to be ot the paint inside is sticking, if it is a enamel or powder coat it is more than likely the second one. and you will have to sand the paint off.

[starwalt]

I have been doing this on my project.  Don't know about your bars but I assembled the switch before and slid them onto the bar. Also there is a lot of stuff inside both switches that can get tangled up and in the wrong place.

Davipu is right about the throttle handle. Try the handle grip without the switch to make sure it slips on the bar with no bind. If OK, assemble with your switch and NO throttle cable to test again. If OK, add the cable. Yes you will be taking it apart again and again but somewhere along the way the problem will reveal itself.

I have too much bind on the stock bar for my project (thanks again for the starter davipu!). All the parts are in the right place. Answer? Silicone Spray! (NOT WD40! Wrong application)

Keep at it!

[scratch]

Did you cut off the locating posts on the insides of the switch assemblies?

[cummuterguy]

if you run a finger inside each of your switch assemblies, you'll feel a small 'nub'.
you either have to file them down, or drill corresponding holes into the new bars. someone on this board once suggested if filing them down, leave just a trace of the 'nub' behind, not enough to cause a gap, but enough to keep the assembly from rotating on the bar.

[matthewlanglois2984]

I took a quick look at the assemblies and did notice the small plastic nubs sticking out this is probably the problem....for some reason didnt notice it before. ill try filing them down a bit and putting it back together. Thanks for all the help everyone