Please help with new handlebar installation

Ski_rush · 05-08-2019, 09:23 PM

I need to replace my handlebars because my old ones are bent. I got the new bars this week (i.e., Tusk T-6 aluminum) and tried to install them today. I was thinking/hoping that this would be a simple bolt-on installation. However, I ran into a snag.

The old handlebar has two pre-drilled holes on the throttle side; I believe that they help lock the throttle in place. See attached pic.

The new handlebar does not have these holes. So...what do I do?

1. Try to drill these holes into the new Tusk handlebar? If so, is there a certain drill bit type that I use? The Tusk handlebar seems pretty thick and is definitely quite a bit thicker than the stock handlebar.

2. Or, do I buy a new throttle that does not need these holes drilled? Are these holes "standard" and they would be required no matter what handlebar and throttle I used? Forgive the newbie questions; I've never done this before and not sure what to do.

Thanks

Megadan · 05-08-2019, 09:33 PM

I honestly see no purpose of the hole all the way on the end of the bar, but the one on the right is there for a locating pin to help stop the housing from rotating.

There are a lot of opinions on the way to go about this. Some people drill the holes, others remove the locating pins from the housing and rely on the clamping force to hold it to the bar. I have done it both ways and never had an issue with not using the pins. The Hawk doesn't even come with them and the controls stay in place just fine. If you find that the controls don't quite clamp down, a small wrap of electrical tape at the outer edges of said housings is often enough to take up the gap and give it something positive to bite into.

Drilling is fine, and since it is aluminum almost any metal rated drill bit will suffice. Start with a pilot hole and work your way up to the size you need. Make sure to center punch the spot you want to drill in order to stop the bit walking and use a slower bit speed. The distance is easy to get right, but figuring out the angle will be the more difficult challenge. Just measure as much as you need and mock it up if you need to in order to get the housing positioned how you want it.

NzBrakelathes · 05-08-2019, 10:52 PM

I think you will find both sides will need a whole if you have swicth gear either side.
Simply mount it no hole n mark where the hole needs to be but be sure the bar is mounted how you like it on the bike, and the switch gear etc so you can see/make impression where the holes need to be

Ski_rush · 05-09-2019, 09:49 PM

I got the drill and the drill bit ready today. The left side also has a hole in the handlebar. I’m assuming to locate/mount the choke assembly that goes on that side. Not sure why, but I can’t seem to bring myself to drill a hole in my new handlebar. Kind of seems like a pain and I’m worried about scratching the crap out of this brand new handlebar.

1. Why does this bike have this, but all the big brand dirt bikes do not? I’ve watched many videos on YouTube about guys installing new handlebars and controls on dirt bikes and not a single one of them have this system with a pin and a hole.

2. If I decide to remove the pins, what’s the best way to do that? Just yank them out with a pair of needle nose pliers?

Megadan · 05-10-2019, 12:04 AM

Quote:

Originally Posted by Ski_rush

I got the drill and the drill bit ready today. The left side also has a hole in the handlebar. I’m assuming to locate/mount the choke assembly that goes on that side. Not sure why, but I can’t seem to bring myself to drill a hole in my new handlebar. Kind of seems like a pain and I’m worried about scratching the crap out of this brand new handlebar.

1. Why does this bike have this, but all the big brand dirt bikes do not? I’ve watched many videos on YouTube about guys installing new handlebars and controls on dirt bikes and not a single one of them have this system with a pin and a hole.

2. If I decide to remove the pins, what’s the best way to do that? Just yank them out with a pair of needle nose pliers?

I find it odd that they used the pins too. You see that more on road bikes from the factory. Like I said, Hawks don't have them, and like you said, neither do most off road bikes. I wouldn't sweat removing the pin.

How to remove it just depends on the housing. Some are press fit and you can pull them out. Others are cast in, and in that case you can grind them down with a dremel.

Douglass · 05-10-2019, 10:19 AM

Quote:

I got the drill and the drill bit ready today. The left side also has a hole in the handlebar. I’m assuming to locate/mount the choke assembly that goes on that side. Not sure why, but I can’t seem to bring myself to drill a hole in my new handlebar.

I had to do that on mine. Just try to find a way to make an accurate mark to drill the hole. When I replaced the handle bars on my sons Apollo Commander, I had to cut off about an inch off each end. That was a little nerve racking for me.

Douglass

OneLeggedRider · 05-10-2019, 12:37 PM

Just remove/grind off the pin, you wont have any trouble with it.

The important thing is the plastic throttle grip moving freely on the bar and returning without any drag consistently. When you let go of the grip it should snap shut quickly.

pete · 05-10-2019, 08:38 PM

Quote:

Originally Posted by Ski_rush

I got the drill and the drill bit ready today. The left side also has a hole in the handlebar. I’m assuming to locate/mount the choke assembly that goes on that side. Not sure why, but I can’t seem to bring myself to drill a hole in my new handlebar. Kind of seems like a pain and I’m worried about scratching the crap out of this brand new handlebar.

1. Why does this bike have this, but all the big brand dirt bikes do not? I’ve watched many videos on YouTube about guys installing new handlebars and controls on dirt bikes and not a single one of them have this system with a pin and a hole.

2. If I decide to remove the pins, what’s the best way to do that? Just yank them out with a pair of needle nose pliers?

Possibly the plastic is that soft or so badly molded they don't clap on the bars
as they should..... after all where was it made...

..

NzBrakelathes · 05-11-2019, 12:10 AM

Without the pins you find the switch gear rolls around the bar
Annoying!
The pins stop that

Megadan · 05-11-2019, 04:02 AM

Quote:

Originally Posted by NzBrakelathes

Without the pins you find the switch gear rolls around the bar
Annoying!
The pins stop that

They usually don't, but it depends on the housing you are starting with. Most controls already grip the bars well enough to prevent rolling in the first place and the pin is mainly put there to ensure proper positioning during assembly for consistency and quality. I have removed the pins from more than one set of switch gear housing when changing bars, and only once was it ever really an issue, and only one one side of the bars in question. I have also drilled many sets of bars for the pins, and while it is simple enough on paper, putting it into practice is something very easy to goof up.

Ski_rush · 05-11-2019, 08:48 PM

Update, you need to drill the holes...and it was super easy. The drill bit poked a hole through it relatively easily. I did not need to center punch the hole.

Also, for anyone who wants to buy the Apollo 250 Deluxe, I recommend upgrading the throttle out of the crate. The stock throttle is the cheapest thin plastic tube that I can imagine using for this. It’s literally the equivalent of a toilet paper tube made out of thin plastic.

05-08-2019, 09:33 PM	#2
Megadan Join Date: Apr 2017 Location: Omaha, NE Posts: 7,994	I honestly see no purpose of the hole all the way on the end of the bar, but the one on the right is there for a locating pin to help stop the housing from rotating. There are a lot of opinions on the way to go about this. Some people drill the holes, others remove the locating pins from the housing and rely on the clamping force to hold it to the bar. I have done it both ways and never had an issue with not using the pins. The Hawk doesn't even come with them and the controls stay in place just fine. If you find that the controls don't quite clamp down, a small wrap of electrical tape at the outer edges of said housings is often enough to take up the gap and give it something positive to bite into. Drilling is fine, and since it is aluminum almost any metal rated drill bit will suffice. Start with a pilot hole and work your way up to the size you need. Make sure to center punch the spot you want to drill in order to stop the bit walking and use a slower bit speed. The distance is easy to get right, but figuring out the angle will be the more difficult challenge. Just measure as much as you need and mock it up if you need to in order to get the housing positioned how you want it. __________________ Hawk Information and Resource guide: http://www.chinariders.net/showthread.php?t=20331 2018 Hawk 250 - Full Mod list here. http://www.chinariders.net/showpost....62&postcount=1 2024 Royal Enfield Shotgun 650 https://chinariders.net/showthread.php?t=34124
	1

05-09-2019, 09:49 PM	#4
Ski_rush Join Date: Feb 2017 Posts: 449	I got the drill and the drill bit ready today. The left side also has a hole in the handlebar. I’m assuming to locate/mount the choke assembly that goes on that side. Not sure why, but I can’t seem to bring myself to drill a hole in my new handlebar. Kind of seems like a pain and I’m worried about scratching the crap out of this brand new handlebar. 1. Why does this bike have this, but all the big brand dirt bikes do not? I’ve watched many videos on YouTube about guys installing new handlebars and controls on dirt bikes and not a single one of them have this system with a pin and a hole. 2. If I decide to remove the pins, what’s the best way to do that? Just yank them out with a pair of needle nose pliers? Last edited by Ski_rush; 05-09-2019 at 11:46 PM.
	0

05-08-2019, 10:52 PM	#3
NzBrakelathes Join Date: Jun 2016 Location: Hell Posts: 2,408	I think you will find both sides will need a whole if you have swicth gear either side. Simply mount it no hole n mark where the hole needs to be but be sure the bar is mounted how you like it on the bike, and the switch gear etc so you can see/make impression where the holes need to be
	0

05-10-2019, 12:37 PM	#7
OneLeggedRider Join Date: Nov 2018 Location: Stockport, Oh. Posts: 1,442	Just remove/grind off the pin, you wont have any trouble with it. The important thing is the plastic throttle grip moving freely on the bar and returning without any drag consistently. When you let go of the grip it should snap shut quickly.
	2

05-11-2019, 12:10 AM	#9
NzBrakelathes Join Date: Jun 2016 Location: Hell Posts: 2,408	Without the pins you find the switch gear rolls around the bar Annoying! The pins stop that
	0

05-11-2019, 08:48 PM	#11
Ski_rush Join Date: Feb 2017 Posts: 449	Update, you need to drill the holes...and it was super easy. The drill bit poked a hole through it relatively easily. I did not need to center punch the hole. Also, for anyone who wants to buy the Apollo 250 Deluxe, I recommend upgrading the throttle out of the crate. The stock throttle is the cheapest thin plastic tube that I can imagine using for this. It’s literally the equivalent of a toilet paper tube made out of thin plastic.
	1