6th Gen Heli Bar Install - See It Before You Try It!

Awesome instructions...thank you. I plan on installing them on my '98 tomorrow.

I do have a question for anybody that has installed them on a 5th gen...is it necessary to remove the top triple clamp to re-route the throttle cables behind the front fork tube? Also, any after pictures showing exactly how the cables are routed after moving them would be most appreciated. I'm sure I can figure it out...but words of wisdom from experience never hurts

Thanks!

Kevin

 

Fantastic write-up, I'm sure I'll be referring to it next weekend when I put mine on my 5th gen.

 

Throttle Cables

I didn't do this. The brake cables extend well in front of the brake hose.

With your method, doesn't the brake hose pull hard on the throttle cables and bend them where they don't want to go? My brake hose snakes tightly around the post.

 

I'll assume you meant your throttle cables extend well in front of the brake line. I followed the Helibar instructions concerning this; ie, I adjusted the brake line so it sits in front of the throttle cable. I had to on mine, otherwise the throttle cable was pinching the brake line and not allowing full adjustment of the Helibar. As long as none of your lines look pinched or stressed by excessive stretching I wouldn't worry about it.

 

Yes, I meant throttle cables. Definitely a different configuration. But no pinching or worries.

Thanks

 

need help

Thank you for this wonderful and helpful topic. I will change my bars by heli. I do not understand what I must remove with the dremel or with a grinder? I have a plastic flex on the fork which retain the cables. I think that I must remove it, but I do not need Dremel.thank for your assistance:crazy:

then VERY CAREFULLY used the grinder / cut-off wheel to remove the brake line locator tab per the heli bar instructions

 

Hi there,

This is on the right side. removing this piece of the casting allows you to loosen the line and rotate it per the instructions.

Hope this helps,

Keith

 

Thank you ottrod, isvery helpfull.
best regards:thumbsup:

 

convertibars

anyone installed convertibars? how do they comparew/ helis?

 

Thanks for the install pics. I think I was done in about 90 minutes. Much more comfortable on the ride after. I think I need to go back and realign the bars a bit though. I may have them a little too far forward.

Dan

 

It took me a while to figure this one out... :crazy: I assumed you were talking about the tab on the lower part of the throttle assembly having to fit into the upper assembly.... To clarify, there is a hole on the bottom of the bar, and the pin on the throttle assy has to go in it

 

I finally had a chance to install the HeliBars on my '07 today. Took probably a couple hours. The only difference that I found was the following... I assumed that the instructions directed you to remove the locating tab on the brake cable because there would not otherwise be enough slack to re-install the master cylinder on the HeliBars. However, my brake cable appeared to have plenty of slack and, since I couldn't find a saw or a cut-off wheel in my dad's garage, I figured that I might as well try it without removing the tab. It seems to have worked. I was able to re-install the master cylinder with no problems, and it doesn't appear to have crimped or stressed the hose in any way. Of course, YMMV.

Actually the issue that I seem to have is with the clutch hose. It seems to be a little tight. I need to look at it in the morning to see if I can get some slack from somewhere, or re-adjust the HeliBars.

Another thing, since I didn't have any alcohol that doesn't come in a 12-ounce can:tongue:, I simply used a small, tiny, miniscule amount of dish soap to re-install the dampers and the left grip. Worked fine, but the grip actually moves now, so I am going to have to clean it and re-do it. Oh, well. Easily fixed.

After the install, I took her out for about a 30 min test ride. Seemed much more comfortable. With the stockers my hand would start to get sore after about five minutes. With the Helibars, no soreness to report. I also have a Sargent seat and a ZG DB screen.

Thanks ottrod

 

After cleaning it, try spraying the bar and/or the inside of the grip with hair spray... borrow it from a girlfriend/wife... It lubricates to help get the grip on, and then sticks once it dries. Works great!!!

 

Thanks for the great idea. I better borrow it from my wife. If I borrow it my my girlfriend my wife might get suspicious!:crazy:

 

Subscribing since mine are coming in this week.

 

Thanks for the writeup. My helibars just arrived from sporttour.com Getting the 'ol die grinder ready to chop off those tabs. I noticed the helibar instructions now say if you have ABS not to move the brake line in front of the wiring.

 

thanks for the info Ottrod. Well done and great job. I plan to install the bars this weekend and also put on heated grips (short season here). Your information sure will help in the process. I also have the zg windscreen and noticed a big difference as well.

 

Thanks for the comments and glad the thread helped you out. I've had my VFR with the Heli bars and ZG windshield for a year now, and am still very happy with the combination!

:thumbsup:

Keith

 

Thanks Ottrod for your fantastic "heli how to". Between your great intstructions and a few other tips like the one from Scoratease I was
able to install my helibars in about 2 hours without too many cuss words.
The left bar dampener gave me a little challenge but what the heck "there
is one in every bunch". Someone else had suggested not to cut the tab off
of the brake reservoir and they were correct. It was not necessary on my
05'. Thanks again for your terrific help with this project.

 

Great write up - Perhaps worth passing on a two points from my install.

I tried to remove the dampers from the bars following the instructions and after getting nowhere fast I gave up and used plan B (which always involves a hammer). I first sprayed WD40 (releasing oil) into the damper, down the various holes drilled into the old bars, and then mounted the bars horizontally in a vice wrapped in an old sock (as I didn't want to damage the vice). I refitted the bar end weight and placed an adjustable spanner up against the end weight. Whilst a friend used a screwdriver to free the retaining tabs I gently tapped the side of the adjustable spanner and in seconds the damper unit slid out. Easy.

Second - removing the tabs may not be strictly necessary BUT its done to ensure there is ample slack on the various pipes and cables. If you don't bother to remove the tabs and adjust the pipe angles as recommended, then its vital you regularly check that they are not chafing anywhere or restricting your steering lock.

Helibars have been the best mod for my bike so far.