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

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How to mount clip-ons? ('76 KZ400) 20 Apr 2024 16:39 #897913

  • TexasKZ
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The length of the bars does not matter. The pin has to be located so that the throttle does not hang off the end,and so that no bar sticks out past the end of the throttle.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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How to mount clip-ons? ('76 KZ400) 20 Apr 2024 16:40 #897914

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Also I'm sure you're right about putting it in a vice, but it's literally the last thing left and I probably should have done it first, though I think getting the clutch on first is the only way to assemble everything. So I'll figure out how to locate it as best as possible tomorrow and use a punch to center it then be really careful cause I don't think I can manage getting it all back off again without braking anything or losing anything.
'76 KZ400

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How to mount clip-ons? ('76 KZ400) 20 Apr 2024 16:41 #897915

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Hmmm good point, hadn't done the spatial math but that makes sense. Will be sure to account for that when I give it a go tomorrow. Thanks
'76 KZ400

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How to mount clip-ons? ('76 KZ400) 20 Apr 2024 16:42 #897916

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Also am I definitely supposed to have an opening and closing cable? Any idea what might've happened to the one I'm not seeing?
'76 KZ400

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How to mount clip-ons? ('76 KZ400) 20 Apr 2024 16:44 #897917

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If you remove the clutch lever and disconnect the wires from the switchgear, you can remove the handlebars without taking anything else off that side.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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How to mount clip-ons? ('76 KZ400) 20 Apr 2024 16:49 #897919

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Also am I definitely supposed to have an opening and closing cable? Any idea what might've happened to the one I'm not seeing?
Somebody was probably too cheap to buy a new on and figured it was irrelevant. Many previous owners are idiots.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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How to mount clip-ons? ('76 KZ400) 20 Apr 2024 16:55 #897920

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Good chance I suppose but where should it have been?
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How to mount clip-ons? ('76 KZ400) 20 Apr 2024 18:38 #897924

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The two cables should be routed side by side from the throttle to the carbs. There should be some pictures in the service manual.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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How to mount clip-ons? ('76 KZ400) 20 Apr 2024 18:53 #897925

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Thanks, looked it up in the manual posted and what's shown is different from what I had prior to taking it apart, see pic below as it's only got one cable going to it instead of two like the manual shows (also makes tank look much worse than it is)
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Last edit: by ThatYeti.

How to mount clip-ons? ('76 KZ400) 20 Apr 2024 19:23 #897929

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The closing cable would screw into the threaded boss just behind the cable in the picture.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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How to mount clip-ons? ('76 KZ400) 20 Apr 2024 19:30 #897930

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Got it, so I definitely don't have one and never have (long as I've had the bike anyway) but the throttle always snapped back into place even without it. So any idea which slot I should be using?
'76 KZ400

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How to mount clip-ons? ('76 KZ400) 21 Apr 2024 01:55 #897933

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Thanks, looked it up in the manual posted and what's shown is different from what I had prior to taking it apart, see pic below as it's only got one cable going to it instead of two like the manual shows (also makes tank look much worse than it is)
WOW, it looks like that bike has been down hard... and this is probably why one of the cables is GONE??! ...or your 400 only needs one cable and this throttle grip is from a 2 cable system? (just speculating)

The 2 cable system is push/pull, there are also 2 points on the carbs where both come together. It's a redundant (sorta) system... pull the tank and  check the carbs?

Got the FSM yet? Check the fuel system...

 
C.
79' KZ650-D2 [fsm] (Max)
83' KZ750-F1 LTD [clymers] (Kay)
82' KZ1100-D1 Specter (another project)
78' KZ650-B2a (J&H, A Project)
91' KZ1000-P (P = parts)
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