Hello,
I am in the process of trying to get my MTD Trail Flite into street legal condition. Found some DOT tires, now onto the hand controls.
It has been difficult finding hand controls that will fit 7/8" bars, that have all the necessary switches, and don't cost a fortune.
Also looking for something period correct. I could prob get new plastic stuff but wanted to see if I could keep it looking somewhat vintage.
Ended up seeing these on eBay a while back, so I bought them.
https://www.ebay.com/itm/Vintage-7-8-mini-bike-handlebar-controls-throttle-lever-assm-universal-ON-SALE/173884104735?ssPageName=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649
If you read the description, you will see that these were designed to be used with wiring that runs inside the handlebars. My MTD has the removable handlebars, and I need those to fit the bike in the back of my Exploder. So i had to modify them and drill 2 holes to put the wiring on the outside of the bars.
Throttle was a real bear, since the housing is not slotted for a cable. Ended up drilling the throttle for a bigger barrel, and cutting the barrel off, and sliding the cable through the housing and then soldering on a brass barrel. Not much room there but it worked out OK.
Made a rectangular hole on the right side to fit a tiny rocker switch. My first thought was for that to be the kill switch, but I think I am going to use that for the 4 way flashers instead and keep the kill switch I already have.
Still have to figure out the mounting of brake light switches on both sides, since both levers are supposed to activate the brake light. I have an idea that I think will work.
Bought 4 small amber lights that I plan to use for blinkers/hazards/running lights. Tested the circuits for the switches on both sides and everything works.
So left side has horn button and Hi/Lo beam switch, right side has L and R blinker switch and 4 way flasher switch. Once the brake switches are installed that should take care of the hardware side of things.
Some pics
Took quite a bit of work, but there is still a bit to go.
For now the wiring is just zip tied to the handlebars in anticipation of building a small fuse box with a flasher and regulator/rectifier and battery. Obviously a ton of wiring needs to be done.
I'm not even sure this will even work, but I'm going to give it a try!
Thanks for reading!
I am in the process of trying to get my MTD Trail Flite into street legal condition. Found some DOT tires, now onto the hand controls.
It has been difficult finding hand controls that will fit 7/8" bars, that have all the necessary switches, and don't cost a fortune.
Also looking for something period correct. I could prob get new plastic stuff but wanted to see if I could keep it looking somewhat vintage.
Ended up seeing these on eBay a while back, so I bought them.
https://www.ebay.com/itm/Vintage-7-8-mini-bike-handlebar-controls-throttle-lever-assm-universal-ON-SALE/173884104735?ssPageName=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649
If you read the description, you will see that these were designed to be used with wiring that runs inside the handlebars. My MTD has the removable handlebars, and I need those to fit the bike in the back of my Exploder. So i had to modify them and drill 2 holes to put the wiring on the outside of the bars.
Throttle was a real bear, since the housing is not slotted for a cable. Ended up drilling the throttle for a bigger barrel, and cutting the barrel off, and sliding the cable through the housing and then soldering on a brass barrel. Not much room there but it worked out OK.
Made a rectangular hole on the right side to fit a tiny rocker switch. My first thought was for that to be the kill switch, but I think I am going to use that for the 4 way flashers instead and keep the kill switch I already have.
Still have to figure out the mounting of brake light switches on both sides, since both levers are supposed to activate the brake light. I have an idea that I think will work.
Bought 4 small amber lights that I plan to use for blinkers/hazards/running lights. Tested the circuits for the switches on both sides and everything works.
So left side has horn button and Hi/Lo beam switch, right side has L and R blinker switch and 4 way flasher switch. Once the brake switches are installed that should take care of the hardware side of things.
Some pics
Took quite a bit of work, but there is still a bit to go.
For now the wiring is just zip tied to the handlebars in anticipation of building a small fuse box with a flasher and regulator/rectifier and battery. Obviously a ton of wiring needs to be done.
I'm not even sure this will even work, but I'm going to give it a try!
Thanks for reading!