Handlebar Expansion??? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 5 Old 04-29-2017, 01:28 PM Thread Starter
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Location: Fort Sask , Alberta, Canada
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Handlebar Expansion???

Do you think it is possible to expand the stock handlebar when tightening up the end bolt used for hand guards??

I ask because for some time (years) my throttle does not snap back as it should when you let it go. Yesterday I had everything apart. Everything checks out to be okay. Throttle cables are lubed, adjusted properly and routed as they should be. I finally got the throttle tube returning when I sprayed some oil between it and the handlebar. When I reinstalled the hand grips I was back to no return. Think I probably answered my own question. Considering the bars are made of tin foil likely need to look an an alternate. Thanks.

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post #2 of 5 Old 04-29-2017, 05:45 PM
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Could it just be rust? I've had more than one pair of bars that I needed? to sand clean in this area.

If the pressure of glueing the grip back on was enough to cause the pinch again I'd maybe consider a new throttle tube. Maybe you've just worn yours down to the point where it's no longer thick enough to maintain it's shape?
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post #3 of 5 Old 04-29-2017, 06:18 PM
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I doubt it klr4evr, but it could be possible for the tapered wedges to bulge the bar.

With the throttle tube/grip assembly removed or slid in-board of the area one could use a micrometer or dial caliper to take measurements.
I also have had to use a strip of sand paper (like shoe shine cloth) to reduce the diameter of the RH side of handlebars (usually painted models).

If the rubber grip hangs beyond the plastic throttle tube it could rub on either the handlebar or the hand guard bar.
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post #4 of 5 Old 04-29-2017, 07:11 PM
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probably not but a decent set of aluminum bars are way bettter than the stock "pasta strength" units anyhow.

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post #5 of 5 Old 04-30-2017, 07:16 AM
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Join Date: Sep 2013
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Could be the closed end of the grip contacting the end of the bar. Try moving the throttle assembly a little more toward the end of the bar.
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