Author Removing controls on handlebar  (Read 929 times)

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  • Offline ibnsneju   us

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    Offline ibnsneju

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    Removing controls on handlebar
    on: Sep 25, 2022, 06.09 am
    Sep 25, 2022, 06.09 am
    Hey guys, anyone know a good resource to find some sort of manual to remove/install the switch controls (for handlebar replacement) ? been looking everywhere on google and cant find anything, possibly googling the wrong thing (maybe it isn't a Z900 specific endeavor)

  • Offline MaverickAus   au

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    Re: Removing controls on handlebar
    Reply #1 on: Sep 25, 2022, 10.11 am
    Sep 25, 2022, 10.11 am
    Undo the 2 JIS screws, they will fall off

  • Offline ibnsneju   us

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    Offline ibnsneju

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    Re: Removing controls on handlebar
    Reply #2 on: Sep 25, 2022, 03.47 pm
    Sep 25, 2022, 03.47 pm
    *Originally Posted by MaverickAus [+]
    Undo the 2 JIS screws, they will fall off

    And just slide the throttle and clutch grip off after removing my bar end mirrors?

  • Offline Cazzy_R   england

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    Offline Cazzy_R

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    Re: Removing controls on handlebar
    Reply #3 on: Sep 25, 2022, 08.53 pm
    Sep 25, 2022, 08.53 pm
    *Originally Posted by ibnsneju [+]
    And just slide the throttle and clutch grip off after removing my bar end mirrors?

    Clutch side switch clamshell:
     Just undo the two screws and open it up. There is nothing to fall out and lose on the floor. Easy.

     Throttle side:
     Remove lever assemblies and RH bar end.
     Partially open up the clamshell by slackening off the two clamp screws but do not split it completely open. Just enough so that it loose on the handlebar.
     Unbolt the handle bar clamp and slide the handle bar towards the clutch slide and out of the throttle tube.
     Doing it this way will leave the throttle tube and throttle cable undisturbed and none of the cables or wires will get stretched.
     However if you are replacing the handlebar with something undrilled you will have to split open the throttle tube which is a little daunting for the first time. Just take your time and perhaps take some photos to help you understand the throttle cable routing. Its pretty straightforward.

      :028:

  • Offline ibnsneju   us

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    Offline ibnsneju

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    Re: Removing controls on handlebar
    Reply #4 on: Sep 26, 2022, 12.04 am
    Sep 26, 2022, 12.04 am
    *Originally Posted by Cazzy_R [+]
    Clutch side switch clamshell:
     Just undo the two screws and open it up. There is nothing to fall out and lose on the floor. Easy.

     Throttle side:
     Remove lever assemblies and RH bar end.
     Partially open up the clamshell by slackening off the two clamp screws but do not split it completely open. Just enough so that it loose on the handlebar.
     Unbolt the handle bar clamp and slide the handle bar towards the clutch slide and out of the throttle tube.
     Doing it this way will leave the throttle tube and throttle cable undisturbed and none of the cables or wires will get stretched.
     However if you are replacing the handlebar with something undrilled you will have to split open the throttle tube which is a little daunting for the first time. Just take your time and perhaps take some photos to help you understand the throttle cable routing. Its pretty straightforward.

      :028:

    Thanks a lot for this. What exactly is supposed to be drilled? I'm getting the clip-ons with the fork adapter plate from aliexpress. I'm also assuming I don't need to remove the grip from the throttle tube, correct?

    this is my first DIY mod and since this deals with the brain of my bike I don't wanna screw it up

  • Offline KellyL   au

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    Re: Removing controls on handlebar
    Reply #5 on: Sep 26, 2022, 12.12 am
    Sep 26, 2022, 12.12 am
    *Originally Posted by ibnsneju [+]
    Thanks a lot for this. What exactly is supposed to be drilled?
    The switchblock has a pin that goes into an index hole in the handlebar. It prevents the block from twisting.

    Some people grind off the pin on the switchblock, but I prefer drilling a hole in the new handlebar as it's safer. It's quite easy to do with a vice and the right drill bit. Just measure thrice and drill once.

  • Offline Cazzy_R   england

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    Offline Cazzy_R

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    Re: Removing controls on handlebar
    Reply #6 on: Sep 26, 2022, 12.37 am
    Sep 26, 2022, 12.37 am
    *Originally Posted by ibnsneju [+]
    Thanks a lot for this. What exactly is supposed to be drilled? I'm getting the clip-ons with the fork adapter plate from aliexpress. I'm also assuming I don't need to remove the grip from the throttle tube, correct?

    this is my first DIY mod and since this deals with the brain of my bike I don't wanna screw it up

     Yeah you can leave the grip on the throttle tube.
     The rest of it is as Kelly said though I drilled the bars in situ on the bike. Centre punch and drill a small pilot and work up from there  I found that 4mm with a generous chamfer was big enough to locate the pin. It's worth doing much better than grinding the pin. Yuck

  • Offline ibnsneju   us

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    Offline ibnsneju

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    Re: Removing controls on handlebar
    Reply #7 on: Sep 26, 2022, 01.38 am
    Sep 26, 2022, 01.38 am
    Is this the hole you guys are talking about on the bars?


  • Offline Cazzy_R   england

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    Offline Cazzy_R

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    Re: Removing controls on handlebar
    Reply #8 on: Sep 26, 2022, 06.44 am
    Sep 26, 2022, 06.44 am
    *Originally Posted by ibnsneju [+]
    Is this the hole you guys are talking about on the bars?



    Yes.

  • Offline ibnsneju   us

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    Offline ibnsneju

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    Re: Removing controls on handlebar
    Reply #9 on: Sep 26, 2022, 04.15 pm
    Sep 26, 2022, 04.15 pm
    Sweeet, hopefully this is an easy install then  :763: