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Throttlemeister installation on a 2002 Aprilia Caponord

April 14, 2011

I’ve used a Throttlemeister on my Aprilia Futura for a couple of years and love it.  It’s a very effective throttle lock (cruise control) and helps to reduce vibration as the Throttlemeister bar ends are significantly heavier than stock.  I’ve ridden the Caponord about 8000 miles without one, but this summer, I’m heading to the north west part of the United States and there are some big states to cross (North Dakota, South Dakota, Montana, Wyoming, Utah, etc.).  So I decided to finally install a Throttlemeister (I’ll refer to it as a TM to save typing going forward). 

Is a TM easy to install?  The answer is it depends.  The installation on my Futura was straightforward, on the Caponord it ABSOLUTELY was not!    The instructions provided by Throttlemeister were absolutely worthless for the Caponord

They described procedures and parts removal that were not even on the motorcycle!  I called them about this and offered to help write a more complete procedure and was essentially told to piss off – they seemed to be absolutely un-interested in fixing the installation directions. 

Minimum tools required:

A Dremel with a metal cutting tip, a drill with a variety of sized very sharp drill bits, shop vac, Loctite blue and red, assorted sockets and wrenches, a small pick to remove the bar end remnants, a thread cutting tap, and a good work light.  You may like different tools, but this worked for me.

The Installation:

Note- a large part of this installation assumes that the reader has a good working knowledge how to fabricate, understands how to adjust a Throttlemeister and can follow the particulars of installing a TM.

I removed the left bar end first and was greeted with what appeared to be a press fit bar end weight.  On closer inspection it appeared that the bar end weight was a permanent install that was machine crimped at the factory and was designed to never be removed.  Ignoring reality, I set out on trying to rig a bar end puller up using a longer bolt, a large socket and a few shims (I got this idea from a few Google searches on pulling the bar-end weights.  Apparently on a few TM installations they provide a machined puller to remove inserts). 


With no more than 4-5 cranks of the socket, the bolt broke off.  Now I was faced with a broken stud and no clear path to removing the weights. 


The only solution was to drill out the entire thing and see if I could somehow make the TM inserts still work. Due to the broken bolt, the left side of the bike was much harder to complete than the right side (as I knew just to completely drill out the entire thing).  The picture below shows the throttle side of the bike being drilled out.  Just use increasingly large drills until you get virtually all of the pressed in bar weight removed. 


When enough material is removed you can begin to pry out the metal insert.  It was rusted an nasty.  I am quite confident that it would have been impossible to use a “puller” or a slide hammer to remove the insert.


Make sure to remove every bit of the insert and vacuum all the metal shavings from inside the tube.


It’s hard to see in the picture below, but the bar-end inserts were inserted and crimp fit into the handlebars.  There are several dimples that go completely through the handlebar and notch into the bar ends.  Clearly, the Caponord bar inserts were designed to never be removed.


After removing the remainder of the insert you will need to Dremel out some of the bar end to allow the tap to begin it’s work.  GO SLOWLY when removing material, you are only trying to remove enough to allow the tap to cut smoothly.


Close up of the tap.  Without this you will not be able to install the bar end adapters provided in the TM kit. 


Use some oil to help the cutting process.  Take it slow and back the tap out every once in a while.  This will help in precise cutting.


It’s not the prettiest thing in the world but the tap worked well.  I used a shop vac to remove all metal shavings from drilling (prior to tapping and after). I also used some brake clean to make sure all the oil was removed from the threads.


I used high strength red Loctite to ensure that these adapters would remain in place forever. This is essentially a one way installation. The picture below shows the completed left side bar end. 


Back on the right side of the bike the next step was to trim the little plastic tabs off the throttle tube to allow for the friction tube to fit properly.  Again, take your time and remove just what you need for a perfect fit.


Friction tube installed.


Looking good and ready to mount the bar adapters.


Bar adapter mounted (and Loctite) on the throttle side of the bike.


The TM installation for a bike with hand guards is different that for a bike without.  You need these extra parts.  A spacer to fit inside the TM and an adapter for the bar end where it meets the hand guard.


The spacer drops into the TM (both sides)


Bar end adapter for hand guard.


The installed product – this is the left side of the bike.



The right (throttle) side of the motorcycle.  This installation show an optional grip wheel.  The grip wheel is to allow easier grip of the throttlemeister.  The hand guard makes it harder to grab the TM.  It’s a fantastic addition.


That’s it!  I’ll post more pictures after I finish test riding it today.  These camera phone pictures don’t really show how great the finished results look.  Now all I need is to pack  up and head out!

One Comment leave one →
  1. Frank Gorshin permalink
    April 14, 2011 9:33 am

    Nicely done…

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