How to mount clip-ons? ('76 KZ400)

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20 Apr 2024 13:56 #897896 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Didn't notice that before on the stock set but appreciate the info. Think I actually got them that way not knowing ahead of time so I'm good there. Everything else is reinstalled but the throttle at this point, do I need to drill a hole for it?

Also any idea how to get the bar end mirror out i just installed in the stock bars? Or are they meant to be one time use?

'76 KZ400

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20 Apr 2024 13:59 #897897 by Wookie58
Replied by Wookie58 on topic How to mount clip-ons? ('76 KZ400)
You need to drill a hole, with the mirrors try loosening the bolt and push it in, they are held with an expanding fitting which you need to release (definitely not one time fit)
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20 Apr 2024 14:01 #897898 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Was hoping I could get away without drilling a hole, how the heck do I figure out where to put it without just eyeballing it?

Will give that a shot on the mirror hardware, thanks

'76 KZ400

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20 Apr 2024 14:39 #897903 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Got the mirror hardware out, good call on pushing it in before trying to get it out.

Any guidance on how to determine where to drill a hole and how big for the nub on the throttle tube?

'76 KZ400
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20 Apr 2024 14:45 #897904 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Also dumb question but which hole does the throttle cab nub belong in?

'76 KZ400

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20 Apr 2024 16:07 #897906 by TexasKZ
Replied by TexasKZ on topic How to mount clip-ons? ('76 KZ400)
Both. The opening cable goes in one and the closing cable in the other.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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20 Apr 2024 16:30 - 20 Apr 2024 16:36 #897907 by TexasKZ
Replied by TexasKZ on topic How to mount clip-ons? ('76 KZ400)

Got the mirror hardware out, good call on pushing it in before trying to get it out.

Any guidance on how to determine where to drill a hole and how big for the nub on the throttle tube?
Here is a way to locate the hole. 
Make sure the bar is located just the way you want it. Put a wide piece, or a couple of narrow pieces of masking tape side by side, where you think the hole will be, then measure from the end of the old bar to where its pin hole is. Make a mark with a pen or pencil or Crayola or whatever. Carefully place the pin on the mark, making sure you have the housing rotated properly, then press the pin against the tape firmly enough to make an impression.
Set the housing aside and use a center punch to make a mark in the center of the impression, then drill a hole the same diameter as the one in he old bar. Remove the tape and test fit the whole assembly.
If your tape is kinda thin, you may need two layers to get a visible impression.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Last edit: 20 Apr 2024 16:36 by TexasKZ.

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20 Apr 2024 16:33 #897908 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Ohhhh that's bad, I'm only seeing one nub.....what does that mean?

'76 KZ400

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20 Apr 2024 16:34 #897909 by TexasKZ
Replied by TexasKZ on topic How to mount clip-ons? ('76 KZ400)
It would be a really good idea to take the bar off after marking it and do the drilling with the bar clamped in a drill press, or at least in a vice.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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20 Apr 2024 16:34 - 20 Apr 2024 16:35 #897910 by TexasKZ
Replied by TexasKZ on topic How to mount clip-ons? ('76 KZ400)
There is only one nub. Once the housing is screwed together, one nub will keep it located.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Last edit: 20 Apr 2024 16:35 by TexasKZ.

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20 Apr 2024 16:36 #897911 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Thanks, and that's kinda what I'd figured I'd do but without the tape so that's a good idea I'll use but the stock bars are a different shape and I think maybe an inch longer so I don't think measuring is going to work unfortunately.

'76 KZ400

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20 Apr 2024 16:37 #897912 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Sorry I meant there's only one nub at the end of the throttle cable, not seeing a second.

'76 KZ400

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