....my mate told me when he got new bars for his Fireblade he had the same issue. So he filed the pins down on the throttle body and ignition and they went on OK. Problem is mine won't grip the bars now. Is there something I can use to make them grip?
Drilling the holes isn't easy and it can be tricky to get them in exactly the right position. Filing the pegs off is often recommended but it is a bad idea. The peg is an essential part of the design and the housings of the throttle and switchgear are not designed to clamp solidly around the bars on their own. To try to tighten them up that much, with (or perhaps even without) a bit of tape or somesuch around the bars to increase the clamping effect, will just cause the housing halves to try to "spread" around the bars. The resulting tensile load on the inside edge will cause the brittle casting to crack. In fact I have just bought a used throttle housing which has a filed off pin and has the resultant crack to go with it (somewhat ironically, just where the pin used to be). But I think I have a solution ... and it should sort your problem too. Drill and tap a small hole, maybe 4mm thread, exactly where the pin used to be, and fit a pointed grubscrew which can be locked onto the bars to stop the housing turning, just like the pin used to do. You could even then drill a small dimple or hole in the position marked by the grubscrew. Otherwise its a new throttle in my opinion. Though even if you do get a new one, I'd be inclined to use the old one with the grubscrew as a device to set up the throttle position and mark the position of the peg hole.
Last time i needed a new clip on I made one out of ally bar, obviously no holes, so I wrapped a piece of paper around the old broken bar and marked the pin holes, this gave me a perfect template to transfer to the new bar. Steve
That's a natty plan. Although it might not be so simple on a "normal" handlebar because you would have to position the hole accurately in relation to the bends, unlike on a straight clip-on.
Try a bit of self amalgamating tape around the bar first, you can pull it tight to make it quite thin, the end then sticks to itself and the resulting wrap is pretty much non-slip. Should do the job.
