Handlebar issues

I have a kz440 and installed new handlebars and while I like the demensions, there are a few issues with them.

The blinkers don't work too well on them and I'm thinking of moving them to the forks but I don't know what size of fastener or where to get them to attach the blinker assembly to the fork.

The handlebars are the right size, but the center of the handlebars is just a hair small and the part where it curves is a little bit fatter than the clamps allow. So I tried to tighten the bolts as tight as possible (leaving a little gap where the bar won't go completely into the holder). One of the bolts broke off in there and I was wondering how to get it off and what I can do to make these bars work.

Thanks for your help.

Post edited by: EasyRider1, at: 2007/12/29 19:22

Hi Easy,

I'm no 440 expert but I'll not let that hold me back.

If you were to mount the turn signals to the forks they would go onto the "Fork Ears" which mount the headlight.

Regarding the bars:

It sounds like the bars you have are not designed to fit your KZ. I can only suggest finding another set of bars that are designed for your bike.

If you've broken off a bolt you'll have to drill it out carefully and use an easy out to remove it.

Upon reassembly pay attention to the arrow that indicates the front of the bike. Tighten the front bolt entirely and then the rear bolt. There should be a gap of about 1/16" at the rear of the clamp when you're done.

Good Luck

KZCSI

I changed the bars on my 1100 and had to relocate the turn signals also. I picked up a pair of stud type lights on ebay and mounted them on the headlight ears. I'll try and post a pic tomorrow.

KZCSI wrote:

Hi Easy,



It sounds like the bars you have are not designed to fit your KZ. I can only suggest finding another set of bars that are designed for your bike.




KZCSI

I bought the bars from z1enterprizes that were supposed to fit a kz440. I really like the bars but I also want them to fit properly.

KZCSI wrote:

Hi Easy,


Upon reassembly pay attention to the arrow that indicates the front of the bike. Tighten the front bolt entirely and then the rear bolt. There should be a gap of about 1/16" at the rear of the clamp when you're done.

Good Luck

KZCSI

So it is normal for there to be a gap?

EasyRider1 wrote:

I have a kz440 and installed new handlebars and while I like the demensions, there are a few issues with them.
The blinkers don't work too well on them and I'm thinking of moving them to the forks but I don't know what size of fastener or where to get them to attach the blinker assembly to the fork.

I replaced the turn signals with ones from ebay. I mounted them where the reflectors were on the headlight brackets. maybe this will give you some ideas

Post edited by: 1982KZ1100D1, at: 2007/12/30 11:27

Hi Easy,

If I remember correctly you had a problem with the curved portions of the bars being too close together, at least that was what I understood. Is this correct?

Yes the top clamp is supposed to fit tightly at it's front end and leave a gap toward the rear. Much like some of the fork caps that hold the front axel.

KZCSI

del

Thanks for the advice everyone. I happened to have two rear blinker stems that I was going to replace the rusty old ones with. Anyway, I pulled the headlight and they mounted in there perfectly! Looks like the headlight mount was cut for these stems (maybe used on other models?) They look and work great.

The only problem I have is with the ground wires. I just sort of pinched them in between the two parts of the blinker assembly where it is tightened. I suppose this will work for now but maybe someone has another idea. Could I just put a few drops of solder in ther and call it a day?

del

Here's a shot of the relocated blinkers:



Post edited by: EasyRider1, at: 2008/01/02 16:29

Post edited by: KZCSI, at: 2008/01/02 20:42

EasyRider1 wrote:

Here's a shot of the relocated blinkers:

That looks sharp Easyrider...thx for posting it.