Built a twist throttle for my son's minibike on Sat. Simple job, limited tools needed.
Simple concept is that turning (twisting) a pipe around the 7/8" handlebars will wrap a connected cable around it and pull the cable.
Speaking of pipe, I used some old stuff laying around:
1. a 1" to 1/2" threaded pipe reducer. drill thru to 7/8". Hand turn into 1" pipe coupling (part #2) and hacksaw the reducer off just where the thread starts to tighten...keep the threaded piece that's inside the coupling.
2. a 1" pipe coupling;
3. a 4" piece of 1" pipe. also, a piece of bicycle intertube to cover the pipe as a grip.
4. a piece of 1" pvc. Ream out ID to 7/8" by hand with drill bit. Sand OD down so it fits in 1" pipe (this goes on outside end of handlebar and supports the end of the 1" pipe)
5. Solder the threaded piece of the reducer to handlebars, slide pvc bushing on to end of bars when bars are cool.
6. Tighten the 1" pipe into the coupling with wrenches, thread the coupling onto the soldered reducer but only so far as it still easily rotates.
7. Bend simple 1/8 x 1" strap to hold end of cable cover and hose-clamp to handlebar.
8. attach the cable ends to pipe reducer and carb.
Now you have a simple twist throttle that won't come off the bars...
Simple concept is that turning (twisting) a pipe around the 7/8" handlebars will wrap a connected cable around it and pull the cable.
Speaking of pipe, I used some old stuff laying around:
1. a 1" to 1/2" threaded pipe reducer. drill thru to 7/8". Hand turn into 1" pipe coupling (part #2) and hacksaw the reducer off just where the thread starts to tighten...keep the threaded piece that's inside the coupling.
2. a 1" pipe coupling;
3. a 4" piece of 1" pipe. also, a piece of bicycle intertube to cover the pipe as a grip.
4. a piece of 1" pvc. Ream out ID to 7/8" by hand with drill bit. Sand OD down so it fits in 1" pipe (this goes on outside end of handlebar and supports the end of the 1" pipe)
5. Solder the threaded piece of the reducer to handlebars, slide pvc bushing on to end of bars when bars are cool.
6. Tighten the 1" pipe into the coupling with wrenches, thread the coupling onto the soldered reducer but only so far as it still easily rotates.
7. Bend simple 1/8 x 1" strap to hold end of cable cover and hose-clamp to handlebar.
8. attach the cable ends to pipe reducer and carb.
Now you have a simple twist throttle that won't come off the bars...
