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Author Topic: getting a handle on handlebars  (Read 501 times)
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mobilebay750 Topic starter
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« on: July 01, 2011, 05:10:55 PM »

As I work through the rebuild on my 91 Nighthawk "craigslist find" one of the replacements required is the handlebar.

The control pods do not bolt completely closed as they should there is about a 1/8 " gap.  I am assuming this is due to the p.o. using bars of the wrong diameter.   

Can anyone tell me what the proper diameter bar fits a 91 Nighthawk?
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JB1290
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« Reply #1 on: July 01, 2011, 05:36:54 PM »

They are 7/8's bars if that is what you are referring to.
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mobilebay750 Topic starter
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« Reply #2 on: July 01, 2011, 05:52:17 PM »

YEs, thanks jb

Been searching for some replacements online but wasn't finding an "exact" diameter. 
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« Reply #3 on: August 23, 2011, 05:22:28 PM »

Check this as well - If I'm not mistaken, the handgrip/control assemblies each have a small locator "bump" that fits into a hole on the OEM handlebars so that they don't rotate. If you have aftermarket bars, they might be 7/8" but might not have the hole in them. if you take a look at the inner rounded part of the controls, you can see if there's a bump, and if your handlebars are missing a hole. If that's the case, you can drill holes in your new bars to make sure the controls don't rotate.
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coffee_brake
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« Reply #4 on: August 24, 2011, 04:32:13 AM »

Check this as well - If I'm not mistaken, the handgrip/control assemblies each have a small locator "bump" that fits into a hole on the OEM handlebars so that they don't rotate. If you have aftermarket bars, they might be 7/8" but might not have the hole in them. if you take a look at the inner rounded part of the controls, you can see if there's a bump, and if your handlebars are missing a hole. If that's the case, you can drill holes in your new bars to make sure the controls don't rotate.

When you drill, I found it helpful to cut a little cross-hatch with the edge of a file, then the drill bit could bite without rolling off the side.

My NH had the little nibs in the controls damaged. To keep the controls from rotating on the bars, I used a scrap of bicycle inner tube around the bar so the controls would grip when tightened. But you won't need this is your control nibs are still good.
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ariwhiteboy
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« Reply #5 on: August 24, 2011, 05:44:05 AM »

When you drill, I found it helpful to cut a little cross-hatch with the edge of a file, then the drill bit could bite without rolling off the side.

That's a good idea...I usually just use a punch to make a small indent where I want to drill, but that's not always precise.
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DWR577
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« Reply #6 on: August 24, 2011, 04:39:28 PM »

As I work through the rebuild on my 91 Nighthawk "craigslist find" one of the replacements required is the handlebar.

The control pods do not bolt completely closed as they should there is about a 1/8 " gap.  I am assuming this is due to the p.o. using bars of the wrong diameter.  

Can anyone tell me what the proper diameter bar fits a 91 Nighthawk?


If it's got the factory throttle on it, you most likely have the proper diameter bars.  The throttle won't fit on over sized bars and won't tighten on undersized bars without some sort of spacer.

If by control pods you mean the brake and clutch lever mounts, that "eyeballed" 1/8" gap is about right -- the gap is a bit less than that but not by much.  Also has about the same gap on the main bar clamps.

If you're talking about the light switch housing and throttle housing then that's a bad sign.   smiler

As others have said the proper size bars are 7/8".
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