"So, you just untighten these four bolts and take off the risers..."
"Now, I just have to take off the controls by loosening the few bolts on the throttle and front brake..."
"Okay, sweet, they should just slide right off"
"I think they should just slide off..."
"...Uh...well...they should...just...slide"

* 5 minutes later *

"These don't seem like they are going to slide off.."


So...
Is there a lock (groove???) or something on both sides of the handlebars that prevents the controls to be taken off?
Please help, pictures?!
 

the clutch side taking off the grip. you basically have to cut it off.  Or you can spray wd40 in there and keep trying to turn until you turn blue.

the throttle side.. you have to disconnect the throtle cable first. then it will slide off.

oh and i hope you already took the bar ends off first.

for the switch housing, you have to remove them, they have a little nipple in them that fits into a hole in the bars

Sweet trick for clutch grip.  spray some wd40 in there, (or you may not need to but i did) and get a friend with an air compressor and use the blow gun fitting to spray under the grip from the thumb side while twisting and pulling to get it off.  with wd40 and air, mine came right off. but the cables, and wiring is too short to slide off while the bars are attached. so you gotta take the four bolts out, slide the bars to one side and take the controls off the other.

I just did my bars today. 

Ahhhhhhhhhhhh, yes, so thats what I was seeing in the handlebar diagram of the OEM bars.
You can clearly see that "nipple" in the diagram....that sucks. So aftermarket bars are gonna be fun to put on.
http://www.mrcycles.com/fiche_section_detail.asp?section=300603&category=Motorcycles&make=SUZUKI&year=2004&fveh=7247

So any suggestions about how I should drill a hole in aftermarket handlebars?

I would use my drill, but make sure you put the hole in the right place

Or just put a series of 20 holes and let the nipple fit into whatever it feels like 
.... Ahahaha

or sand of the nub on the controls, its just plastic. mines off, previous owner did so i dont know how easy it is, but its just plastic so no big deal.  The controls arent going anywhere so long as you tighten the screws.

Yeah, I just cut the nub off my controls with an x-acto knife, It's a lot easier than drilling your bars. I don't have any problems with mine moving without it.

Alright, that sounds good too guys! Thanks for the advice! 

I'm not sure I like a thread where folk are talking about cutting off nipples with an X-acto knife...

When I've drilled holes, I've located the spot by putting a dab of paint on the doodad and putting the controls where I want them.  Drill where the paint hits.

Thats a pretty good idea, but you never know how much the controls will slide after you actually try to fit the grips....

P.O did that to mine and I had to re attach a nipple because no matter how tight we got it it still slid around esp when trying to put the choke on in the morning.

To each his own

Mary

 
Crap.
Should have been patient with that dremil.

Quote from: Toogoofy317 on October 19, 2009, 06:20:02 AM
P.O did that to mine and I had to re attach a nipple because no matter how tight we got it it still slid around esp when trying to put the choke on in the morning.

1. You can re-attach a nipple after it's cut off or broken off? How - where do you get that piece of plastic, and how do you re-attach it?

2. I know on the right side, the starter/kill switch has a nipple that fits into a hole in the handlebar. You mean on the left side, the choke also has a nipple that fits into a hole in the handlebar to prevent rotation?

fyi on the removal of grips (even though seems like you already got it, but fyi in the future): http://www.youtube.com/watch?v=sf-EKwyER74

i made my "tool" out of an old hanger. i used wd40 once, but honestly i'd recommend hairspray if you're gonna reuse the grips. my bloody grips twist around every so often.

cheers,
~drin

Quote from: drincruz on October 19, 2009, 12:59:13 PM
fyi on the removal of grips (even though seems like you already got it, but fyi in the future): http://www.youtube.com/watch?v=sf-EKwyER74

i made my "tool" out of an old hanger. i used wd40 once, but honestly i'd recommend hairspray if you're gonna reuse the grips. my bloody grips twist around every so often.

cheers,
~drin

+1 for hairspray. aquanet works great.. and when you put the grips back on again, spray a little (it sets like glue after a a while) in there to slip it on.

if you really want them to stay, wire tie em.

all the other stuff has been covered

Mine took a couple swear words to get off, but they worked.  I sanded down the nipple on the housings to, works like a charm and hasnt moved yet....but will now just cause I said that.

Ahahaaaaaaaaaa, of course, of course, thats how it alllwayyyyys works.

Just before my crash, I was telling my buddies,
"Wow, how have none of us crashed yet? Look at how we drive...its incredible that we aren't dead"
*One day later*
"....oh....crap"

We took a small screw tapped it into the nipple area then used a pair of wire cutters to cut it off at the appropriate length. Easy Peasy!

Maybe its just the girl in me but I don't go nuts removing things. usually they are there for a reason

Mary