| ZR-7
Handlebar Replacement
For those interested in replacing the stock
handlebar with an aftermarket bar of some sort, here are some tips to
make the process easier.
Steps
to replace the stock bar:
1/2) Put the bike on it's centerstand!
1) Remove the allen screws from the clamps
holding the mirrors/levers on the bars. Carefully lower the
mirrors down and let them hang by the cables, being careful not to
scratch the tank.
2) Remove the left-side grip from the
bar. If you are discarding the grips and replacing with
aftermarket ones, then you can just cut it off with a utility
knife. If you want to preserve the grip, then you'll need a
solvent of some sort. I use golf club grip solvent, but rubbing
alcohol will work too. Get something that you can bore under the
grip (I use an awl). Use the tool to slide under the end of the
grip and then squirt some of the solvent in there. Twist it
around and keep sliding the tool in farther and squirting more solvent
until you can get the grip to slide off the end of the bar.
3) Loosen the screws in the back side of both
control housings until you can get them to spin freely on the
bars. There's a notch in the control housings that fits into a
small hole drilled into the bars, so you just want to loosen them
enough to get that notch out of the hole. Don't take them
completely apart, or you'll have to mess with reseating the throttle
and clutch cables, which can be a pain.
4) Remove the bar clamp bolts and take off the
top side of the bar clamps. Now the bar will be totally free.
5) Move the bar to the right, and slip the
left-side control housing off the end of the bar. Then move it
to the left and do the same thing with the right-side control housing
and throttle grip. Just like with the mirrors, make sure that
when you slide them off they don't bang against the tank when the
fall.
6) The bar is now off, so you're 1/2 way done.
7) If you're replacing with an aftermarket bar,
you'll need to drill holes in the new bar to accommodate the control
housings. Measure the distance from the end of the bar to the
holes in the stock bar. Use a 7/32" bit to drill holes in
the new bar EXACTLY the same distance from the end of the bar.
Make sure the holes you drill in both sides of the bar are on the same
horizontal line on the bars. Place the stock bars right next to
the new ones when determining the location of where to drill so you
can visualize the alignment.
8) Slide the control housings onto the new bars
in the exact opposite sequence that you removed them. Don't
tighten the control housings yet, just get them slid onto the bar
ends.
9) Put the top half of the bar clamps over the
new bars on tighten the four bolts PART WAY, just enough to hold the
bars in place but still allow them to rotate forward and back when you
push on them.
10) Sit on the bike and experiment with the
forward/backward rotation of the bars until they are in the spot you
like best.
11) Tighten the bar clamp bolts to 17 ft-lbs.
each. Tighten the front bolt on each clamp first, then the back
bolt. If you don't have a torque wrench and are using the
seat-of-the-pants torquing method, 17 ft-lbs. is "more than
finger tight" but less than "putting your weight behind the
wrench" tight.
12) Rotate the control housings until the notch
seats inside the holes you drilled in the bars, and then tighten the
housings. Check the seating of the clutch and throttle cables to
make sure they're still aligned with the cable channels coming out the
back of the housings. You may need to monkey with them a little
if they've come out of their seats. Tighten the control housings
good and tight.
13) Swing the mirrors/levers back up and mount
them right up against the control housings. Put the front side
of the clamps on and tighten them PART WAY. Sit on the bike and
rotate them forward or backward until they're in the spot that suits
you best. Then tighten the clamps good and tight so they won't
rotate any more.
14) Put the grip back on the left side using
more of the solvent. Wet the bar with the solvent, and also wet
the inside of the grip. Then just slide the grip in place up
against the control housing.
15) If you've used aftermarket bars, you'll
probably have also purchased new bar ends, so you can now mount those
too by sticking them in the ends of the bars and tightening the
screws. The stock bar ends are almost impossible to remove from
the stock bars, and they are threaded in a way that they are not
reusable in any aftermarket bar, so don't even bother trying to get
them out.
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