06 Clip on/throttle replacement help - 600RR.net
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post #1 of 7 (permalink) Old 03-15-2014, 04:44 PM Thread Starter
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06 Clip on/throttle replacement help

Long story short previous owner dropped the bike. I'm in the middle of replacing the clip on but can't get the ignition start box to close properly around the bar

I took a pic, there's a little round steel thing with the blue paint on it. It's sticking up and is binding on the bar, not letting me tighten the controls back together

Suggestions please

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post #2 of 7 (permalink) Old 03-15-2014, 05:38 PM Thread Starter
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I'm guessing it's to line up with the holes on the handle bar itself to keep the control from sliding back and forth. Was a pita...after struggling for an hour I still can't get it
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post #3 of 7 (permalink) Old 03-15-2014, 07:08 PM
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yes that pin locates ina hole in the clipon. those pins are normally plastic. looks like maybe the PO has drilled the housing and fitted a metal pin which could be too big for the hole in your bar.
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post #4 of 7 (permalink) Old 03-15-2014, 07:33 PM Thread Starter
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I'm guessing so. There is no way to close the engine control properly because the pin won't sit in the hole of the clip on
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post #5 of 7 (permalink) Old 03-15-2014, 07:43 PM
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either pull the pin out or enlarge the hole. (or buy a new throttle housing)
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post #6 of 7 (permalink) Old 03-15-2014, 09:02 PM Thread Starter
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I ended up just using the old clip on, it only had a small bit of rash on it. With the new throttle tube you couldn't even tell. Once I pulled the new one off that didn't fit, I compared them and the holes were in completely different spots.

What a pita. Took all of about 15 min to get it all done once I realized the new one wasn't going to work.
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post #7 of 7 (permalink) Old 03-16-2014, 01:31 AM
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normally , you just drill a hole where the new pin wants to fit.....

Have seen clip ons w/ 2-3 holes drilled in them...... last long time if holes not drilled around tube at same distance from end....
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