1" Handlebars on my 78 XS650?

[Flash1977]

I have seen that this has been ask before, but I have sofar not found an answer so.... I have a custom 78 XS650 hardtail I have been building and posting pictures of for the last couple years now. This year I decided to have a hand made set of handlebars made to fit the bike made with 1" tube so that I would have access to a larger variety of controls , levers ,ECT. So anyways the question I have is , is anyone aware of a throttle that will work with the stock cables? Also I say that I have put a new 1 into 2 split cable on going to a set of mechanical carbs , but the place that they hook up to the throttle is stock in appearance. Also I am aware that I can buy 1" throttles, I have one. I need one that has the single cable pull as well as the screw down that secured the cable to the throttle. I am also aware that I could probably modify the end of the throttle cable to match a Harley-Davidson throttle but I would really like to just find a 1" throttle that works. Thanks.

 

[Wingedwheel]

I would think any of your aftermarket single pull throttles would work.
https://www.dimecitycycles.com/hand...ntrols/throttles.html?product_list_order=name

 

[Flash1977]

I would think any of your aftermarket single pull throttles would work.
https://www.dimecitycycles.com/hand...ntrols/throttles.html?product_list_order=name

No they will not. That's why I'm asking.

 

[Wingedwheel]

What’s the issue? Is it the Ferrule? I guess I’m not understanding what’s not working.

 

[Flash1977]

What’s the issue? Is it the Ferrule? I guess I’m not understanding what’s not working.

The throttle cable is secured with a small plate and a screw. I can't find this type in a 1"

 

[Flash1977]

The throttle cable is secured with a small plate and a screw. I can't find this type in a 1"

 

[Flash1977]

Here is a pic of an OEM throttle assembly. Notice the small plate and screw that secure the throttle cable

 

[Flash1977]

And here's another pic of the current aftermarket throttle assembly I'm using . I need a 1" assembly but can't find one

 

[Wingedwheel]

I’ve found those to be more of a compression fit. You probably won’t find one with a tab to secure the cable. Most are click in or have a ferrule that fits over the cable for a screw in connection.

 

[Flash1977]

All of my xs650 are that way including the one that has an aftermarket

I’ve found those to be more of a compression fit. You probably won’t find one with a tab to secure the cable. Most are click in or have a ferrule that fits over the cable for a screw in connection.

version on it currently. The cables on the stock are built for that and the cable I bought new is built for that the cables actually have a little lip or ring on them specifically for that . Are you saying your xs650 is different?

 

[Wingedwheel]

No not different, I’ve just used several aftermarket throttles and maybe it was because they were inexpensive but that lip at the end of the cable always worked as a compression fit. I never had issues with it coming out.

 

[Flash1977]

No not different, I’ve just used several aftermarket throttles and maybe it was because they were inexpensive but that lip at the end of the cable always worked as a compression fit. I never had issues with it coming out.

Ok

 

[Flash1977]

No not different, I’ve just used several aftermarket throttles and maybe it was because they were inexpensive but that lip at the end of the cable always worked as a compression fit. I never had issues with it coming out.

So would you take a pic of yours so I can see?

 

[Wingedwheel]

I’m not running one right now but this is the best pic I have of a past one. The end of the sleeve fit inside the fitting and friction and cable adjustment held it in
It’s not perfect by any means but it worked.

 

[Flash1977]

So unfortunately it doesn't work . Not in anyway. Infact there is no part of it that fits . The cable doesn't fit threw any of the fittings, and even it it would it is definitely not tight enough to say put simply by just sitting there. Furthermore the 1 inch throttle control cable is is in a little different position that may or may not work . So right now I have close to 1000 $ in parts I can't use for no other reason then I can't find a 1 inch throttle controll that works with the 78 xs650 single to dual pull cable. I am going to keep working on it but in the meantime if anybody has actually used 1 inch bars with there xs650 successfuly and can share the throttle they used I would appreciate it . Thanks.

 

[Flash1977]

I’m not running one right now but this is the best pic I have of a past one. The end of the sleeve fit inside the fitting and friction and cable adjustment held it inView attachment 326351
It’s not perfect by any means but it worked.

Are these one inch bars?

 

[40north]

If I was doing it from scratch I expect I have fitted 7/8 tube into the 1 inch tube and brazed the transition so there was a pretty radius...then off to spew more money at the chrome shop. Yeah, this doesn't help, does it?

Making up control cables... back in the day the BSA shop at the end of my street simply had a bench and stock of little bits, cable, cable housing, etc etc...and made up the cables. I don't believe there were ready made cables that shops stocked. That situation may exist today in some industrial hardware supply... check McMaster Carr, etc. I used to buy the bits for various projects. Years later I made a few bits in my shop, little lathe, etc, for a project 45 WL. That worked ok.

If using single pull cable be very sure about the return spring set up. Once I went for a wild ride by ignoring that little itty bitty trivial detail ! (only once!)

I admire your initiative, brother.

 

[Wingedwheel]

Are these one inch bars?

No but if you found a sleeve that worked could you make your own cable with the correct ends?

 

[Flash1977]

If I was doing it from scratch I expect I have fitted 7/8 tube into the 1 inch tube and brazed the transition so there was a pretty radius...then off to spew more money at the chrome shop. Yeah, this doesn't help, does it?

Making up control cables... back in the day the BSA shop at the end of my street simply had a bench and stock of little bits, cable, cable housing, etc etc...and made up the cables. I don't believe there were ready made cables that shops stocked. That situation may exist today in some industrial hardware supply... check McMaster Carr, etc. I used to buy the bits for various projects. Years later I made a few bits in my shop, little lathe, etc, for a project 45 WL. That worked ok.

If using single pull cable be very sure about the return spring set up. Once I went for a wild ride by ignoring that little itty bitty trivial detail ! (only once!)

I admire your initiative, brother.

No but if you found a sleeve that worked could you make your own cable with the correct ends?

 

[Flash1977]

So I have been trying to avoid cut the brand new cable that works perfectly in every way until I change Handlebars. I have done it many times and do have the soldering pot and the form . With that said I am really just trying to find a simple fix . It would be great to just find a throttle thats similar. I did end up drilling the fitting on the one inch throttle and making it fit but I still don't like the fact that it's just sitting there I wrapped it so it fits snug but still. Also the whole thing sounds about rattly. I don't know if it's because the Harley tube is for a push pull and I have a pull only cable but most likely the distance of the cable that would normally keep it tight is a little off. When I started this project I mistakenly thought the tc bros built there xs650 with a black 1 inch set of handlebars which would mean they had a solution. Apparently I was wrong. The joys of building a custom bike.