'65 Honda Trail 90 Rebuild - Filed under 'handlebar'

Throttle and entire handlebar assembly removed

Today I disconnected the throttle and removed the entire handlebar assembly. It's looking less like a motorcycle every day. The cables are definitely all going to require replacements. This was also a reminder that when I last worked on this engine back in 1984, I broke the throttle cable retainer. I wedged the two broken pieces into the handlebar tube to get by, but it was a short term fix. Back then, there was no worldwide web for average people to use, and certainly no eBay nor Craigslist. A replacement is < $5 on eBay, which would have been nearly impossible to find back in the 80s.

Dad is now clued into the project. It was going to be a surprise, but it'll be more fun to have him helping with it. And as you can see from the bars below, his expertise in metal fabrication will help when it comes to refinishing chrome surfaces like the handlebars.

Click here to download:

Throttle_and_entire_handlebar_.zip (2812 KB)

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Filed under // cables handlebar Honda Honda 90 throttle

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Left handlebar disassembly

The handlebars are next up for removal. This involves the electrical system a bit earlier than I had hoped, but it's pretty straightforward since it only involves disconnecting stuff. I did the left side yesterday, which controls the headlight/high-beam and horn, plus a brake cable.

It looks like the brake lever and housing can probably be cleaned up and re-used. The handlebar itself is deeply pitted with rust. I found a NOS handlebar online for $44, which will be cheaper (by far) than trying to re-chrome the rusted handlebar. Grips should be easy to find. The mirror is gone but I've already found a replacement.

Tonight I'll try to do the right side of the bar, which includes the front brake and twist throttle.