GPZ550 Cable Lengths (Clip-ons)

You probably ought do the steering stop first to avoid any mishaps w the clip-ons. At the least you could try pvc tubing from the hardware store. As per scirocco's suggestion, I would install a metal sleeve over the steering stop & use a set screw to keep it in place. you'd have to drill & tap a hole for the set screw. use a thread locker on the threads.

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Maybe glue a piece of thick rubber hose over it. Not as permanent as metal, but might work just the same.

Like Scirocco said, you want some kind of bushing on the stop pin to make it bigger.

I've done many. I strongly recommend getting it welded. Setscrews will hold it in place for welding, but will not hold it permanently. Vibration will make it fall off eventually. I've brazed one on before with oxy-acetylene. That worked ok but eventually came off in an accident... a very bad accident where the frame was totalled.

I see the paint looks good, so it will be more work to paint it after welding, but it's worth it.

Maybe there is a way to drill a hole all the way through the stop pin and just put a bolt through it for the yoke to hit. There is not much room to work up in there.

Also, once the steering is stopped down, you can use a wider range of steering dampers since the travel will be a more normal range. There is a lot involved with that since the oil-cooler is in the way, but at least you can start planning now that the travel is set.

The cut surface goes up against the frame.

Once it's in place you can sand it down just enough for the steering lock to still work.
You can also sand down the steering lock stop to make it still work.
There is plenty of play for the steering lock, so sometimes it might still work without doing anything.

Lou, as he so often does, has offered the professional, permanent solution. I would put that at the top of my list.

Hey lou,

thinking about doing the clip ons soon,

www.globalindustrial.com/product/itemKey/30263565

Will this shaft collar work for the stopper?

Hopefully my cheap rotary tool will be able to cut it

Yeah, the link says the OD is 1-1/8". That's about 28.5mm.

All it takes is a good hacksaw and 5 or 10 minutes with a steady hand. A file can clean it up easily.

You will want to take off the zinc plating in the welding areas, and remove paint from the end of the stop on the bike.

It might be better to find one in raw steel. It will weld nicer and you won't have to worry about the plating. Then just paint it with a brush to stop it from rusting.

This one would be better than the zinc plated one. It is difficult to see if all the zinc is off. This black oxide is much easier to see and I think may be less problematic for welding.
www.globalindustrial.com/p/motors/collar...rew-collar-gsc-062-b

Thanks for the quick reply, canceled the order on the zinc plated ones, and ordered two of the other ones just in-case.

Might be a week or two before I get it and put them on, but i'll def be back to update on how it goes.

Thanks again.

If I remember, I will try to get better photos of the stop installed.

Hey Lou,
possible to get pics of your clip on set-up? haven't received the set screw yet, but curious as to how much clearance is taken away using the shaft collar.

Here's a general location I was looking to put my clip ons . ( I know it's quite the turn radius sacrifice)

That is a lot of pull back. Have you ridden with bars set up like that before? My wrists would be hating that, especially on the throttle side.

I have had some pretty deep clip-ons on an sr400 before, but not and this angle.

Really like the way it looks, so i was gonna give it a shot, and if I dont like it i can always change it.

plus these clipons have a little bit of a rise to them, so i figured the angle wouldnt matter too much as long as im not putting too much weight onto my wrists.

That does look pulled back too far. I think it would hit the tank at that angle.

My buddy has the same clipon setup as me, and his blog gives a good Idea of the clearance you can expect.

kz550a.blogspot.com/search?updated-max=2...tart=7&by-date=false

I took some photos of my red bike, but it's hard to get a sense of the angles when the camera is that close. It would be better to take photos from far away and then zoom it in.