I cut and pasted this from the Tiger1050 forum where I posted it in October last year.
How to make a 1/4 turn throttle yourself.Tools needed:-
Phillips screwdriver.
10mm and 8mm spanner.
Hacksaw
stanley knife
Araldite or similar glue.
medium grit sandpaper.
35mm UPVC plumbing pipe.
Stage 1, removing the throttle tube. loosen the cable adjuster in front of the ignition barrel. Unscrew the two phillips heads screws from the throttle housing and remove. Split the housing and remove the cables. Remove the bar end weight and Slip off the throttle tube.
And here it is!
Stage 2, making the throttle spacer. You now need to get yourself some 35mm UPVC plumbing pipe. Mine was 2mm wall thickness, but there is plenty of room for much bigger. I cut a piece of pipe 1/8" wide or thereabouts with the hacksaw and sanded the burrs off. Cut a slot in the pipe so that it looks a bit like this.
Then trim the piping so that it fits snug onto the throttle housing with no gaps.
Just like this.
Once the fit is right, lightly score both the outside of the throttle body, and the inside of the pipe to give the glue something to grip to, and use an epoxy resin type glue such as Araldite to bond the piping in place. You can see in the photo that I made a little cutout guide for the cable to track along. Not really necessary with pipe this diameter, but I did it anyway.
Then leave it to dry. Once dry, trim off any excess glue from the end and inside the tube recess where the housing fits just to make sure it doesn't snag. You can use the stanley knife and sandpsper for this.
Stage 3, the refit
Refitting is just as easy as disassembly. Place the throttle tube on the bar, refit the cables, clamp the housing over the top and place the screws back in tight. Adjust the cable to your desired tension, refit the bar end and Voilla!! Instant 1/4 turn throttle! There is enough room in the housing for much thicker tubing to be used, which will further reduce the ammount of tube travel to give you full throttle, but that's up to you to experiment with it. I'm happy with this much turn, as will most of you.
Enjoy!
