straight bar conversion,

[timbertops]

Hi, any ideas to help with straight bar conversion. both clutch and brake pipes seem too short, tried jaws instructions for clutch pipe, but flexy clutch pipe is totally separate from the brake pipe so its no help removing bolt holding brake pipe.
On brake side it dont look long enough to reach.
I can see jaws supply longer clutch line so that would be next plan, but not sure best option for brake side.
was trying to keep all pipes as standard as possible in case ever sold the bird ( very unlikely ) and new owner wanted standard bars back on.
Thanks in advance.

 

[Gary Bartley]

Installed the bars myself a few months back and had the same issues.

For the clutch line I messed around with it for a while but in the end I just ordered the 60mm longer braided line off Jaws which worked a treat and is a nice upgrade to the bike anyway.


For the front brake, I just released the brake hose from brake clamp on the lower front fork yoke and left this line loose. This gave me enough length and It doesn't foul anywhere on the forks/bodywork etc.

I also replaced the throttle cables with 60mm oversize from Jaws as I wasn't comfortable with the pressure on the existing cables on full lock with the suggested routing.

Hope this helps a bit@tu*

 

[timbertops]

cheers mate, thought clutch would need 60mm upgrade, will try the brake option tomorrow before ordering the clutch pipe. many thanks.

 

[Howard]

You can cut the tabs off the master cylinders to rotate the lines and get a bit more length, also you can undo the front brake lines from the bottom yoke and just use cable ties to hold them.

 

[timbertops]

thanks, cutting the tab off might help, tried the brake method, think it might work but is now against the fork tube. the 60 mm extra long clutch pipe looks the plan for other side but the ends on the jaws pipe are different to ones on the bird, can't see how they fit.

 

[CBRDEAN0]

thanks, cutting the tab off might help, tried the brake method, think it might work but is now against the fork tube. the 60 mm extra long clutch pipe looks the plan for other side but the ends on the jaws pipe are different to ones on the bird, can't see how they fit.

IIRC the jaws picture is NOT what arrives - the extended clutch line has std banjo fittings at each end.
It completely replaces the whole clutch line from the master cylinder down to the slave cylinder.

 

[Gary Bartley]

IIRC the jaws picture is NOT what arrives - the extended clutch line has std banjo fittings at each end.
It completely replaces the whole clutch line from the master cylinder down to the slave cylinder.

That's 100% right - easy enough to do too and you will also replace the clutch fluid in the process which is a good thing anyway.

See below a couple of photos of mine loosely fitted whilst I was in the process of routing the line. Make sure to fit the new copper washers that come with it to both sides of each banjo @tu*

 

[timbertops]

Thanks guys, the info and pics are a great help, already ordered the clutch line and was concerned about ends, phoned jaws up and they said it would fit, still not sure till i read your tips. thats all i am waiting for now, not sure how long post is but. Cheers all.

 

[timbertops]

clutch line worked fine, still not ideal lever positions, can't get them high enough, without binding on throttle cables and mirror cover, might come to extra long throttle cables yet, any tips guys.

 

[Gary Bartley]

clutch line worked fine, still not ideal lever positions, can't get them high enough, without binding on throttle cables and mirror cover, might come to extra long throttle cables yet, any tips guys.

I am using short levers myself but I also had issues with the brake lever being too low for me and clearance between the lever and the throttle cables.

Fitting the longer throttle cables wont solve this issue but along with the extended clutch line, will certainly help to keep the movement of the bars nice and free and not restricted in any way.

I loosely fitted everything first, then I rotated the throttle housing up enough to allow me to also rotate the brake lever clamp up enough for the lever to be comfortable and yet clear each other. Then I drilled the bars for the locating the switch and pin. Not sure what you can do if have already drilled and fixed the position.

Here's a couple more photo's I took for you last evening showing what mine look like in the finished position. You will probably notice that I have also rotated my bars slightly forward of the vertical, this is for comfort but the throttle housing to brake lever clearance should still be relative.

I also fitted the Jaws mirror extenders as all I could see in them after fitting the bars was my arms

Sorry I can't be of any more help to you on this, this was a big learning curve for me too:-0)

Gary

 

[timbertops]

cheers mate, very good pics helped a lot, can live with settings as now but might try short levers and mirror extenders,

 

[Dickiebird]

Bloody big moths where you live, Gary . Are they indigenous to your part of the Emerald Isle?

 

[Gary Bartley]

Bloody big moths where you live, Gary . Are they indigenous to your part of the Emerald Isle?

@tu*

You bet - sure you can see the emerald green on the wing tips :-0)