Removing throttle

[phire]

What kinda work is involved in removing the throttle grip off of the handlebars? My bar end on that side fell off and I have no idea how long but obviously long enough for it to get wet in the rain and start rusting... So, I want to remove the throttle and sand it down and put some rustoleum or something to keep it from rusting more. I did buy new bar ends, but I'd like to take care of the rust that's seeping under the throttle before I put em on.

[DerekNC]

It's very simple. Just off the top of my head I think there's 2 or 4 screws holding the assemble together. Just remove those screws from the housing and it should split apart. Now you can slide the grip assembly out of the housing. I can't remember for sure but you may need to slide the cable out of the grip assembly to get it off the handlebar. There's not really anything in there that's going to jump out when you pull it apart so you'll see how it goes back together.   

[starwalt]

As above, yet you will have to deal with the throttle cable(s) that run to your carb. Later models, 2001 + have two cables off the throttle grip.

The rubber of the grip slides onto the plastic throttle handle. That handle is interlocked on the RH control assembly by the two haves of the same assembly. The handle needs no lubricant to move well on the handle bar. A little teflon spray on the plastic parts that clamp around the handle is fine.

I noticed the paint on stock bars leaves a lot to be desired in quality. You should be able to rub the rust off, apply a primer, LET IT CURE OVERNIGHT, then apply your finish coat and LET IT CURE OVERNIGHT before reassembly.

"Dry" paint often out gases for days after it seems dry. The pros often speed up the process with heat. Take your time and it will be fine.   

[phire]

Gotcha. It was an easy removal and really there's only one way it can be put back on now that I've had the chance to look at everything disassembled. Spent 5 minutes with the Dremel and the round sanding tool which fit perfectly inside the bar to clean out the rust inside. Almost hate to paint it now it's all shiney and new looking again.

starwalt- You don't think just sanding it down good and putting a few coats of Rustoleum will suffice? No one is going to see where I'm doing this at since it's under the throttle. I'm just doing this to prevent the whole entire bar from rusting out over time on me. I may re-paint the whole bar in the future but as for right now, I'm just going after the quick fix with what I have in the garage. Planned on painting it before I went fishing for shims and letting it dry while I do that and run to the store for stuff and possibly let it just sit overnight.

[starwalt]

Well....after it is no longer sticky, or "dry", wait overnight and then take a hair dryer to it for several minutes. Don't scorch it, of course. Anything is better than bare nothing so the quick fix will do you well for a long time.

Riding is way better then painting anyway! 

Then if -- God Forbid -- you drop it or it falls over and bends the bar, you will have to get a new one anyway. 

[sledge]

This is where all the people who put high strength loctite, instead of low strength or a few turns of PTFE tape on the bar end weight screws to stop them backing come unstuck by chewing up the screw heads while attempting to remove them