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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