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Old 22-07-09, 10:18 PM   #1
Specialone
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Default Help needed on handlebar conversion

Howdy,
Just spent last few hours trying to get my new handlebar kit fitted.
Got most of it done even without any instructions being sent, but i have few queries.
1, They supplied 2 braided brake lines similar in length, i presume these replace the manifold or whatever its called which is mounted on front fender (or mudguard) and fits directly to the calipers rather than through the manifold or splitter.
There is a double banjo bolt which i think goes lever end and 2x single banjos which i presume goes on the calipers.
Is it a good idea to re-use the rubber sleeving and run the new hoses through these to prevent any chaffing.
2, No clutch cable was supplied so i presume again i dont need one, does it just need re-routing?
The only way i can see the clutch cable working is if it routes straight to the lever when it leaves the hole by the tank instead of going through and round the forks.
Can somebody in the know please confirm if i'm barking up the right tree?
Very difficult doing a job like this because a, for the first time and b, with no instructions whatsoever.
Thanks
Phil
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Old 23-07-09, 01:23 AM   #2
Bibio
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Default Re: Help needed on handlebar conversion

you are correct about the brake lines.

as far as i know you will need longer clutch and throttle cables if you want to route them properly (might be an MOT fail if you dont). you may also have to detach the control wiring from the block mounting under the tank (i had to and i only have adjustable clipons)

i'm surprised that the longer throttle and clutch cables were not supplied in the kit.
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Old 23-07-09, 09:17 AM   #3
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Default Re: Help needed on handlebar conversion

yes double banjo to master cyl'.....single to each caliper, and yes u lose all the rubber hoses/splitter etc....i used ss p clips to hold the brake lines tidy to the forks etc, as for clutch line, yes re-route back thru the forks and go direct from headstock to bars' this is how i did mine and works fine, i also managed to re-route the throttle cables and they also work fine on full lock either direction, mines just passed its mot too'''..my upbar conversion cost me less than £100 for all the bits i needed, as i was gonna order the 998 kit..anymore questions just ask
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Old 23-07-09, 09:32 AM   #4
Nicky S
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Default Re: Help needed on handlebar conversion

what kit have you got i undertsnad the brake lines (and yes you have got that right) also i take it you have the washers as well.

but i dont see why u would need new clutch cable got laods of room on it the only problem i had was my throttle cables being pulled tight and sticking.

can we have some more info on your kit please becuase if your jsut sticking renthals on it then you dont need to change much also what bike is it ?
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Old 23-07-09, 11:31 AM   #5
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Default Re: Help needed on handlebar conversion

my throttle cables arnt pulling...works fine..all depends how u re-route them, i came out the right side of headstock instead of usual left hand side...works for me, and like i say its just passed its mot..now im really enjoying the naked upright position after 26 yrs of sportsbikes etc
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Old 23-07-09, 02:08 PM   #6
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Default Re: Help needed on handlebar conversion

Quote:
Originally Posted by Nicky S View Post
what kit have you got i undertsnad the brake lines (and yes you have got that right) also i take it you have the washers as well.

but i dont see why u would need new clutch cable got laods of room on it the only problem i had was my throttle cables being pulled tight and sticking.

can we have some more info on your kit please becuase if your jsut sticking renthals on it then you dont need to change much also what bike is it ?
I have the kit from 999cc.com which supplied renthal bars, braided s/steel hoses and banjos, washers etc, longer throttle cables, yoke, risers, new grips and no intructions for a 09 k7 sv650s.
Throttle cables are done and working, stock clutch cable is quite short and will not reach unless re-routed.
The throttle cables would have worked i think just coming out of the right rather than the left because there aint a lot of difference between the new and stock.
Phil
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Old 23-07-09, 02:11 PM   #7
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Default Re: Help needed on handlebar conversion

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Originally Posted by lee67 View Post
yes double banjo to master cyl'.....single to each caliper, and yes u lose all the rubber hoses/splitter etc....i used ss p clips to hold the brake lines tidy to the forks etc, as for clutch line, yes re-route back thru the forks and go direct from headstock to bars' this is how i did mine and works fine, i also managed to re-route the throttle cables and they also work fine on full lock either direction, mines just passed its mot too'''..my upbar conversion cost me less than £100 for all the bits i needed, as i was gonna order the 998 kit..anymore questions just ask

Thanks mate, apreciate it.
The present brake hoses run through rubber sleeving by the headstock which i presume is for wear resistance, anti chaffing etc, is it wise to run the new braided hoses back through these?
Phil
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Old 23-07-09, 05:16 PM   #8
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Default Re: Help needed on handlebar conversion

i didnt, i just fixed em using a ss p clip, to the original fixing point just below the headstock...and also used p clips to hold the lines down the forks ie use the orignal fork fixing points looks very tidy
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Old 23-07-09, 05:25 PM   #9
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Default Re: Help needed on handlebar conversion

The clutch cable will have to be re-routed with the ABM kit to give you enough reach to the bars .
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Old 23-07-09, 05:54 PM   #10
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Default Re: Help needed on handlebar conversion

ive told him that already
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