Right hand control - throttle cable cover cap problem

[Rintintin]

Happy Friday. Who is ready for spring already?
This past weekend, I was doing some winter preventative maintenance and upgrades on my 2006 Mastiff when I hit a snag...

I took my right hand control apart to 1) replace the original throttle grip with a new one from HDM and 2) rebuild the front brake master cylinder. I got the throttle grip replaced just fine; but I could not figure out how to remove the c-clip from inside the confines of the front control body. My c-clip pliers would not reach.

I gave up on the brake master cylinder rebuild for now and put the assembly back together. When I was tightening the bolt (part #19 in the diagram below) into the throttle cable cover cap ( #14 in the diagram below) when the head of the bold sheared off after being screwed all the way in and on final tighten. The head and about 2 threads is all that broke off.

Everything works fine, but I'm not sure where that leaves me. I would love to hear some of your experience and ideas:
1) Does the throttle cable cover cap serve a functional purpose or is it mostly for looks?
2) After the bolt broke, I tried to slide the throttle cable cover cap out and it does not seem to be coming out, so is it ok to leave it as is for now?
3) When I actually have to rebuild the front brake master cylinder at some point, how can I get the remainder of bolt 19 and the throttle cable cover cap out to take the assembly apart?

Thanks.

Dave

 

[Rintintin]

Hey guys. I spoke with Tim at Bog Dog Motorcycles about this. He stated that the Throttle Cable Cover Cap's primary purpose is to keep debris and foreign materials from entering the throttle cable area.

That is good news. However, I still have the problem of how to remove it when I do need to at a later time. Unless there is a better suggestion for removing the broken bolt, I guess I will have to drill it out.

Big Dog Motorcycles actually stocks the Throttle Cable Cover Cap, so I ordered a replacement. They did not stock the bolt, so I am going to source it from a local HW store (10-24x1" SHCS Stainless) and be ready when I need to go back after the master cylinder.

 

[Th3InfamousI]

Hey guys. I spoke with Tim at Bog Dog Motorcycles about this. He stated that the Throttle Cable Cover Cap's primary purpose is to keep debris and foreign materials from entering the throttle cable area.

That is good news. However, I still have the problem of how to remove it when I do need to at a later time. Unless there is a better suggestion for removing the broken bolt, I guess I will have to drill it out.

Big Dog Motorcycles actually stocks the Throttle Cable Cover Cap, so I ordered a replacement. They did not stock the bolt, so I am going to source it from a local HW store (10-24x1" SHCS Stainless) and be ready when I need to go back after the master cylinder.

#14 you are referring to the thottle cable cover? I would say it's primary purpose is the channel the throttle ferrules rides in without that your grip could get stuck while riding, or ferrules can jump out....No Bueno...

#19 is the broken bolt? The mirror bolt? That wouldn't be a 10-24?

Snap ring pliers on the front are kind of non-standard, need to have long enough ones to reach it.

 

[Rintintin]

Hello Th3Infamous1. Yes, on that diagram, #14 is the Throttle Cable Cover Cap. It is still firmly in place, but I will be more diligent in making sure it stays secure. The broken bolt is the one that goes into the Throttle Cable Cover Cap - not the mirror bolt. I'm sorry if I mis-referenced it from the diagram.

I'll search for some L O N G snap ring pliers. Glad to know.

Thanks for the response!