Handlebar problem!

[ThinkAgain]

I'm trying to fix enough damage from my wreck for my bike to be rideable, but I'm not bothering with scuffed plastic bits or the paint job, for now.

I had weird handlebars that were on the bike when I bought it.  The thing looked like clip-ons but was one piece.  It gave me more of an agressive posture than I liked, so I'm not terribly bothered having to replace them.  

I bought the OEM bars from Ron Ayers and I'm having trouble getting everything square.  There are little holes drilled in the bars that correspond with little pegs that protrude from within the handlebar controls (turn signal & starter).  These have to line up for the electronics to be properly seated above the grips, but mine don't line up!  I positioned the bars where they will be comfy (and where it looks like they look on pictures of other bikes), but the guide holes are about 90 degrees to the front of the bars.  If I set the pegs in the holes, then I can't operate the controls (they are facing the sky!).  But if I set them in the holes and try to tilt the handlebars back far enough so the controls are facing me, there isn't enough slack in the cables to move that far AND the grips are uncomfortable.

Does anyone know what I'm doing wrong?  I have pictures of the bars, but nowhere to display them.  I can e-mail them if the description above isn't clear.

Thanks, Scott

[ThinkAgain]

I just posted a photo on the Wall of Fame under Member's Bikes.  It shows three angles to hopefully provide a good look at the problem.

Any ideas?

[JasonB]

easiest way to fix this is shave the nubs off and put them where you want. Or drill new holes in the correct spot.

[ThinkAgain]

I had thought about drilling new holes, but never had much luck drilling on a hardened, round surface.  If I cut or sand the little pegs off, will the instruments tighten down enough?  I'm not worried about them moving along the handlebars since they'll be sandwiched between the grips and the brackets that hold the levers/mirrors.  But will they keep from spinning in place? Should I put plumber's tape on the handlebars where I want the controls to sit?

[klimber]

when I bought new handlebars i had similar questions,

i just shaved the nubs down with a dremel and tightened the controls down.  it's been several months and nothing is spinning on me yet!  and i didn't put any pipe tape on, just tightened them down.

maybe a wrap of tape couldn't hurt though, you never know!

[ThinkAgain]

Thanks, I appreciate the advice from both of you!  Hopefully I'll be out on the roads again soon!

[Jared]

Drill Drill Drill.... don't cut the locater pins off.  Get a centerpoint drill bit or a centerpunch and take your time. The controls don't always tighten up enough  and you'll find the throttle will roll around the bar on you.

[JasonB]

I only had a problem on the clutch side I stripped the bolt holding the clutch lever on, so I bought a longer bolt and put a nut on the other side. Never had a problem with anything else.