DIY- Woodcraft Clipon Install

[zev42]

1.) Ok, tried loosening the other bolts, but those got stripped too. Seems like the bolts are very very soft, because I applied almost no pressure and the bolts just gave in.

2.) I bought a Black & Decker bolt extractor from Walmart, $10, and followed directions. After hammering the bolt extractor inside the drilled hole, I began to turn the extractor, and SNAP! The bolt extractor tip snapped and is lodged inside the bolt!

Since the bolts have loctite applied to them, is this what is making it so difficult in getting the bolts out?

Also, I've noticed that red fluid began dripping from the screws... is that the loctite? I have no clue what the red fluid is. I didn't cut any lines, I'm simply trying to get the bolt out and now I've got red fluid on my fingers, and no, it's not blood.

Help please? :-)

[g21-30]

Red loctite, once hardened, will not flow. You must USE HEAT to break the seal! Without heat, it is even more difficult (which you are finding out) to remove the screws. Others have resorted to cutting the bar ends off with a hacksaw, i.e. cut almost to the center all around the bar ends. Then slip them off and use a vise grip to unscrew the screw, after heating.

[kkim]

Did you use red loctite or blue loctite?

[zev42]

Blue loctite, as recommended by the instructions that came with the clip-on's.

Applying heat to break the seal... will it be ok to use a lighter or blow torch, or is that a horrible idea? I don't know if loctite is flammable.

[g21-30]

Propane torch is OK. Normally, blue loctite doesn't require heat. It is designed to be disassembled via normal tools. Give the heat a try.

[zev42]

Will do! I'll try it out when I get home from work. :-D

[kkim]

Yes, try heating it and be careful to keep the heat away from the plastics for the allens that does not have the extractor lodged in it. For that one, you should get it on the work bench to attempt removal.

Also, make sure the hex head of the Allen wrench you are using is fully inserted to the bottom of the screwhead and be sure you are applying pressure at 90* to the bolt and not from an angle.

[rockNroll]

What size allen wrench are you using, and is the tool is good shape? The bolts that came with mine don't seem soft and I did tighten/loosen them a bunch of times.

[zev42]

Yea I'm using the proper sized allen wrench. The tool is brand new :-)

The bolts on the right clip-on came off easily. I don't understand why I'm having trouble with the bolts on the left.

[Justanothermp5]

yea those bolts are really soft, when i took the stock bars off i found the red loctite was actually really easy to break loose

u can use like a lighter or a heat gun to soften it up and if that doesnt work...idk lol

[danknation]

I have something I need clarification on. I have been reading about clip-ons in various areas and have found conflicting information. Is it possible to install the woodcraft kit without raising your forks? I thought I read in a few places that people had to raise their forks in order to get the clipon on mount.

[rockNroll]

Originally Posted by danknation

I have something I need clarification on. I have been reading about clip-ons in various areas and have found conflicting information. Is it possible to install the woodcraft kit without raising your forks? I thought I read in a few places that people had to raise their forks in order to get the clipon on mount.

No need to raise the forks for the woodcraft clip ons.

[F3nrir125]

Originally Posted by Lukey

sorta... dont have a torch so thought a soldering iron would get some heat - but as i thought; not enough! my mate came around today and removed them with an impact wrench!

anyway so ive just finished putting them on - pretty fiddly! one problem occured; the tightening mechanism for the clutch (as in the bolt that tightens the clamp to the bar) has stripped and will only tighten so much, but not enough. how would i fix this?

I don't have a torch as well so being a daring person I used my portable stove.

[zev42]

The bolt is still in there, but I managed (with a help of a friend) to get the other bolts loose so I could wiggle the clip-on to a better position. Used a torch to help get the other bolts loose.

The stubborn bolt looks like a root canal that had horribly gone wrong, lol!

[mikedabike64]

great write up looks pretty mean too.

[RRTRIDER]

Thanks for the write up KKim. This motivated me to buy a set and the cycle control rearset adjusters. How are those adjusters working out for you by the way? I just ordered a set from Richard. Good reviews!

[kkim]

I have adjusted to the clipons and have just recently readjusted the footpeg adjusters back a notch. Bike is feeling quite good.

gl w/ your install.

[RaceBikeRentals]

Originally Posted by RRTRIDER

Thanks for the write up KKim. This motivated me to buy a set and the cycle control rearset adjusters. How are those adjusters working out for you by the way? I just ordered a set from Richard. Good reviews!

[jamesbernatchez]

I ordered from Richard and got them in last night. Thanks Richard! I followed this install thread some and found it pretty easy to do. I used a torch on the bolts for the stock ends. Held the torch on for less than a minute, put the screwdriver in and gave a good wack with a hammer and they came off with almost no effort. Thanks to both of you!

[RRTRIDER]

hey james! thats awesome. im trying to take my bar ends now to make installation easier when i get the receive the clipons. i held the torch for a long time, heated it pretty good, wacked it many times but it still wont budge. any suggestions?

[Lukey]

hope i'm not highjacking this thread too much, but, kkim you have the front of your ninja lowered correct? I'm thinking of doing this as well in conjuction with having clip ons on; to give me an even more aggresive riding position. is it as simple as removing the front fairings and dropping the suspension to the desired amount?
the only diy thread ive seen on lowering the front utilises roaring toyz lowering blocks...

sorry. but thanks.

[kkim]

yes, I have my front forks dropped in the triple clamps. (not pictured in this DIY) I think they stick out about 1.5 inches to further quicken the steering. very good mod to increase the bikes "flickability".

if you look closely you can see how much I presently have the forks sticking up above the triple clamps.

[Lukey]

Originally Posted by kkim

yes, I have my front forks dropped in the triple clamps. (not pictured in this DIY) I think they stick out about 1.5 inches to further quicken the steering. very good mod to increase the bikes "flickability".

if you look closely you can see how much I presently have the forks sticking up above the triple clamps.

thanks for the response! Yeah easily notice the difference. This is definately something I'm gonna do to my ninja. At higher speeds does the bike become unstable? And on a scale of 1 to 10, how difficult would doing this be? Considering the most diy I've done is fit a tail tidy, rim stickers and slip on exhaust... Thanks again, always a help.
Posted via Mobile Device

[jamesbernatchez]

Few better photos of my Clip-Ons

[jamesbernatchez]

Originally Posted by RRTRIDER

hey james! thats awesome. im trying to take my bar ends now to make installation easier when i get the receive the clipons. i held the torch for a long time, heated it pretty good, wacked it many times but it still wont budge. any suggestions?

What kind of torch? I used a propane torch and when I removed the flame there was smoke coming from inbetween the bar end and the grip, probably cause the threadlock was getting so hot. Don't be afraid to hit it to hard either. I gave it a few really good whacks.

[untdavid]

I finished my clipon install, but the brake line seems to touch the speedo when turned to full lock. Can you adjust the brake line so that it won't loop around so much? I know there is a gommet and bracket holding the brake line down. Can I adjust the slack by adjusting that? Thanks.

Picture taken from Zartan's DIY Raised Fork post.



David

[kkim]

can you take a picture of the brake line touching the speedo?

[untdavid]

Sure, I'm at work surfing the forums. I'll take some when I get home.

[untdavid]

Here are the pictures of the problem I'm having. How do I get the brake line out of the way? Its a annoying problem but doesn't affect me that much. Is my clipons installed incorrectly?

Thanks for any help or advice anyone can give me.

David

[JaeL]

and the problem is?

[rockNroll]

I wouldn't sweat it... mine touches at full left too. It must touch if I have the clip on's and levers where I want them.

[Perbeils]

Originally Posted by kkim

yes, I have my front forks dropped in the triple clamps. (not pictured in this DIY) I think they stick out about 1.5 inches to further quicken the steering. very good mod to increase the bikes "flickability".

if you look closely you can see how much I presently have the forks sticking up above the triple clamps.

Hi! I just installed the WC clipons. They´re very nice, and I loved the riding position.


Can you make a DIY to how to drop the front forks?

Thank you very much!

[kkim]

Just follow this DIY on how to drop/raise the forks. You just need to loosen the pinch bolts on the triple clamps to allow the forks to drop. Just be sure to do one side at a time and do it slowly. Once you drop it more than you want, it's sort of difficult to get it back up w/o a front steering stem stand or something similar. Also, I wouldn't advise going more than 1.75 inches, which is what I have mine set to now.

http://www.ninjette.org/forums/showthread.php?t=9804

[Perbeils]

Originally Posted by kkim

Just follow this DIY on how to drop/raise the forks. You just need to loosen the pinch bolts on the triple clamps to allow the forks to drop. Just be sure to do one side at a time and do it slowly. Once you drop it more than you want, it's sort of difficult to get it back up w/o a front steering stem stand or something similar. Also, I wouldn't advise going more than 1.75 inches, which is what I have mine set to now.

http://www.ninjette.org/forums/showthread.php?t=9804

Thanks. Pretty easy.

But I looked more carefully and looks like it has less than 0,5cm of space left with the clipons. If I raise de forks I´ll have clearance problems at full lock

Thanks anyway.

[kkim]

I don't have any clearance problems with my setup. why would yours be different?

[Perbeils]

Originally Posted by kkim

I don't have any clearance problems with my setup. why would yours be different?

I really don´t know. I´ll take some pics to show you.

[Perbeils]

Originally Posted by kkim

I don't have any clearance problems with my setup. why would yours be different?

you´re right! I just lowered 2cm and it was fine and no clearence problems.

As soons as stop raining I´ll test this mod to see how it handle.

Thanks

[sixstring]

So i bought the woodcraft clip-ons a while back but since its too cold to ride now, I've been working on my bike and finally got around to installing them.

So there are a few issues that I came across.

1. I can tilt the front brake lever down A LOT more than the clutch lever. What I find is that the wires that are coming out of the controls (high beams, horn, turn signals) hit the front of the clip-on risers. It doesn't look like there's a way around this but maybe some people on the forums have seen something I'm missing. I REALLY like the tilted forward angle of the brake lever and its a shame I can't get the clutch lever to match it.

2. I've raised my forks and I'm not sure if this is too much. There is about 1 inch sticking out from the triple. Looking at some other forum member's bikes I'd say that shouldn't bee too big a deal but when I go to lift my bike onto front stands, the top of the stand really starts to push on the underside of the front cowl.

3. While raising my forks, I used a tape measure to see how far above the triple they've been raised. Is that accurate enough? Is there a better technique to ensuring the forks have been raised an even amount? How much of a margin for error can be tolerated?

Thanks in advance.

[kkim]

1. a picture of the problem?

2. I have mine sticking up about 1.5" above the triples. It sounds like you need to adjust your triple clamp stand. I do have a problem w/ my stand hitting my front fender, so I just remove it whenever I lift my bike using the triple clamp stand.

3. a tape measure should be fine.... that's what I've been using.

[sixstring]

Hi Kimm,

Here are some pics of problem 1.

From this pic, you can see amount of tilt the right controls have and how little the left controls have.



From this pic, you can see the problem that I was referring to. If you try to rotate the controls any more forward, the cables end up rotating backwards and getting caught on the clipon raiser.



Here's another perspective of the probelm area

Thanks for your help