Help for possible warped grip assembly? - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 11 Old 02-07-2011, 08:51 PM Thread Starter
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Help for possible warped grip assembly?

Gents and ladies,

I've had a sticky throttle issue for months now and finally decided to look into it. Upon taking the throttle grip/handlebars apart, I found some problems.




I know the previous owner dropped the bike on that side and it looks to me like it warped the whole assembly resulting in a throttle assembly that's less than round. Could this cause the sticking? After taking all that crap off, the throttle has a lot more snap to it, but it still hesitates more than I'd like.

What are my options here? It's quickly approaching the point where I'm not confident doing a whole lot more, and I'm supposed to be riding it across the country in 8 days.

If I do end up taking this in to have it fixed, what work should I expect to be done and a ballpark $$?

Cheers,

Jason

2005 DL650
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post #2 of 11 Old 02-07-2011, 09:12 PM
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If that is the stock bar end........hard to tell from that picture and it has been a while since I had one apart....it shouldn't effect the throttle operation if installed correctly. The shaft is secured by the nut and bushing inside the bars separate from the throttle assembly.

Are you aware of how that threads in and out? Straighten your bolt.

04 Wee with all kinds of excess crap..
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post #3 of 11 Old 02-07-2011, 09:24 PM
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Look real close at the end of the handle bar. Make sure it isn't damaged. the throttle tube shoud be loose on the handle bar. You should be able to wiggle the grip, and throttle tube assembly. There should be play between them. Make sure the grip hasn't slid on the throttle tube, and is contacting the handle bar, or bar end weight. I think I would replace the bar end weight, but could be repaired. You could probably find a replacement real easy without going to the dealer. Some people have replaced them for various reasons/mods.
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post #4 of 11 Old 02-07-2011, 11:22 PM Thread Starter
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Quote:
Originally Posted by AppGap View Post
If that is the stock bar end........hard to tell from that picture and it has been a while since I had one apart....it shouldn't effect the throttle operation if installed correctly. The shaft is secured by the nut and bushing inside the bars separate from the throttle assembly.

Are you aware of how that threads in and out? Straighten your bolt.
My thinking here is that over time, the misaligned bolt (and subsequent bushing/nut) assembly inside the throttle tube might have forced the throttle tube into more of an oval shape rather than round. Inside the grips, this might have caused enough pressure on the throttle tube walls to make a sticky throttle scenario. When I took the grips off (which were on very tight), I released enough pressure to free the throttle a bit. Just conjecture.

I've taken the tank off and from the throttle return spring assembly, everything works like a dream. It's only when the grip is brought into play that the problem exhibits.

2005 DL650
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post #5 of 11 Old 02-08-2011, 12:03 AM
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Have you removed the throttle tube yet? It's easy--two screws out of the throttle case assembly. See if there is crud built up between the tube and the bar, and look closely to see if the tube is warped. If it is straight but dirty, clean and maybe lube with a dry lube...powdered graphite for example...nothing that will hold grit. If the tube is warped, junk it.

When you reassemble, adjust the throttle cables according to the owner's manual. A too-tight return cable results in a sluggish return.

"Older people who are reasonable, good-tempered, and gracious will bear aging well. Those who are mean-spirited and irritable will be unhappy at every period of their lives.

"Let each of use properly whatever strengths he has and strive to use them well. If he does this, he will never find himself lacking."

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post #6 of 11 Old 02-08-2011, 10:33 PM Thread Starter
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PTRider,

I did that with great results...no more sticky throttle. My new question: In doing this process I decided to get rid of the heated grips from the previous owner and go back to regular grips. When I put the new ones on, they're so loose they rotate fully on the throttle. I've got them on the correct side of the bike (larger one for throttle), and even though I know I'll be using adhesive for the final application this seems waaaay too loose. Is this normal?

2005 DL650

Last edited by JGuthner; 02-09-2011 at 10:43 AM.
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post #7 of 11 Old 02-09-2011, 10:42 AM Thread Starter
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So, after 2 days of I found the problem.

I bought 1" grips.

They must have been stocked with the 7/8" ones since I checked the tag multiple times. Oh well, chalk it up to a $14.99 lesson learned. Back to the store I go.

2005 DL650
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post #8 of 11 Old 02-09-2011, 10:58 AM
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Quote:
Originally Posted by JGuthner View Post
PTRider,

I did that with great results...no more sticky throttle. My new question: In doing this process I decided to get rid of the heated grips from the previous owner and go back to regular grips. When I put the new ones on, they're so loose they rotate fully on the throttle. I've got them on the correct side of the bike (larger one for throttle), and even though I know I'll be using adhesive for the final application this seems waaaay too loose. Is this normal?

It's very common for people to grind the ridges of the plastic throttle tube in order to install the heated grips. The OEM rubber grip will not fit back on the tube tight after the tube ridges have been ground off.

DL650A K7
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post #9 of 11 Old 02-10-2011, 10:28 PM Thread Starter
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Ridges are still there, the throttle assembly seems to be untouched. I bought 7/8" grips and they seem to too tight, although I suspect they are exactly how they're supposed to be. I just haven't done this before so everything seems new and harder than it should be.

On a side note, finding 7/8" cruiser grips with a decent amount of cushion and open ends seems to be impossible.

2005 DL650
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post #10 of 11 Old 02-11-2011, 12:12 AM
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Hair spray or metholated spirits on the inside of the grip, line it up and push it on square about 1/2" then give it a good straight, sharp bang with the palm of your hand to send it fully home. Just cut the ends out of blanked cruiser grips with an exacto knife, and make sure the grip end isn't rubbing on the bar weight or rubber on the throttle side. You may have to cut it round at an angle to give the clearance. Grip Puppies over the standard grips are another solution.

(Did you remove the whole bar-end weight as a unit or just unscrew the bolt? If the latter, then the nut and clamp will still be in the bars. Feed a yard or so of 1/4" plastic tube through the bars from the other side to push them out.)

Last edited by scrivens; 02-11-2011 at 12:24 AM.
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