Join Date: Jun 2010
Location: Skippack, PA, USA
Mission accomplished. The installation of two left ends in the left and right handlebar ends is relatively simple. The left (clutch) side is, of course, the easier installation.
NOTE: Locate the heat wiring before cutting anything! (ignore this if your grips are unheated) Cut away the spider covering the opening at the end of the grip. An Xacto blade or something similar is the best tool - not a razor blade or box cutter - a relatively narrow but long blade is the best choice here. Remove one strut at a time, working carefully around the grip heater wiring (nick a wire and you're in very deep sauerkraut!). Throttlemeister's instructions seem to suggest cutting off the entire end of the grip but that's not needed on either end. Just open the grip end to about the diameter of the handlebar tube.
Follow the instructions with the grips to position the insert in place (and don't crimp or crush the wiring!). Run the hex screw in eight turns with a 3/32" hex driver (a short one is included but a longer T-handle driver is easier to use). There will be a lot of resistance as the screw cuts into the inside of the handlebar tube, Do not apply more than ten turns to the screw (or it'll come out the other end of the insert - Not A Good Thing). Run the end's mounting bolt through the end and slide on two thick washers (save the two shim washers for the throttle grip) - screw the bolt into the insert and check that the grip isn't crushed to the point of bulging.
If everything checks out, unscrew the bolt and slide the bar end out with the bolt, to keep the washers in place. Apply Loctite® Threadlocker Blue 242® (not supplied with the ends but you do have some anyway, right?) to the end of the bolt and attach the bar end to the insert.
The right or throttle side is a little harder to work with because it's imperative to keep the throttle free from any drag. Begin as with the left grip: locate the heater wiring, and cut away the spider as with the left grip.
Following the drawing in the instructions, locate the cutout in the insert so that the heater wiring can move freely as the throttle grip is turned from closed to full open. A little experimentation will be needed to get the position right but a bright flashlight on the work area should show where the wires and insert meet as the grip moves.
With the insert properly located, apply eight turns to the 3/32" hex screw as before. The next step is to shim the inside end of the bar end so it doesn't bind or rub on the throttle grip. Throttlemeister recommends a clearance of about the thickness of a credit card between the grip end and the inside of the bar end. Use a combination of the two remaining thick washers and two shim washers to get this thickness. Be very, very sure the throttle grip can turn freely when released! A stuck, open throttle could ruin your whole day. Screw the bar end bolt down tightly and check that the grip can still move freely. Once the proper clearance is achieved, back out the bolt, apply Loctite® Threadlocker Blue 242® to the end of the bolt and tighten it up.
That's it - job done.
Not all who wander are lost. Which still leaves room for more than a few lost wanderers...
Red Flash - '03 K1200RS, lightly farkled