I had a little time to tinker today and thought I would mock up the hand controls today. What should have been an easy task turned out to be anything but!
The problem was there was not enough clearance between the throttle cable cam and the inside of the throttle housing. Once I clamped the throttle housing down on the handle bar the throttle would not turn freely. The Rizoma grips are supposed to be "universal" and come with a series of different sized cams to fit in different housings. However, even with the smallest diameter cam it was rubbing inside the housing. I thought I could file down the cam a bit but there just wasn't enough meat on it so I turned my attention to the throttle housing. The first throttle housing I tried was an Emgo Chinesium unit that really didn't work well at all. I got a second housing from Motion-Pro which fit a little better and the throttle turned but still rubbed . I guess I could have put shims between the throttle housing halves to give some clearance but that would have opened up a gap along the split line and would drive me nuts. So rather than surrender I made a fixture for the throttle housing (upper half only) and using the boring bar on my lathe I was able to open it up a tad and now everything works the way it should. It was frustrating but I should no better by now that every piece of Chinesium I buy just doesn't cut it! As for the Motogadget pushbuttons, bar end signals, and mirrors ... always top notch stuff!
