DIY- Woodcraft Clipon Install

[Matt_F]

I just installed these clip-ons this weekend and I thought I would add my 2 cents here to help anyone out thinking about getting these.

First off, just a little about me: I'm 6'2" and this is my first bike.

The first thing I was worried about was removing the bar ends, because I didn't have a torch and I saw everyone complaining about how hard they are to remove. I thought about it for a minute and then came up with an idea that worked PERFECTLY with NO heat! I used a pair of channel-lock pliers on the handle of my large phillips screwdriver. I've included a pic to see what I mean. I kept pressure on the back of the handle with my right hand and turn the pliers with my left.

My first impression while riding is that I feel MUCH more comfortable on the bike in ALL types of turns. Low speed turns, faster turns...they all feel much more comfortable to me now. Maybe because the clip ons allow me to stretch out more, or maybe just the feeling of being lower on the bike...whatever it is, I like it.

They do reduce comfort some while riding the straights, but not bad and I think I'll get use to it. I rode to work today (almost 40 miles one way) and even had my backpack on with my laptop and accessories in it and when I got to work I noticed no dis-comfort. I'm even thinking the increase in lean has made the seat more comfortable (maybe because the seat is sloped forward so much?). I didn't notice as much dis-comfort as I usually do with the seat on a long ride (already ordered a corbin, but maybe its not needed now? Time will tell.)

[247Nino]

Originally Posted by Matt_F

The first thing I was worried about was removing the bar ends, because I didn't have a torch and I saw everyone complaining about how hard they are to remove. I thought about it for a minute and then came up with an idea that worked PERFECTLY with NO heat! I used a pair of channel-lock pliers on the handle of my large phillips screwdriver. I've included a pic to see what I mean. I kept pressure on the back of the handle with my right hand and turn the pliers with my left.

I also used this method.

I am 5'4" and I feel no discomfort, I have also been riding for about 8 years but my 08 250R is the only bike that had ape hangers.

I love the Woodcrafts

and thank you to KKIM for this write-up!

[250rinblack]

Ordered my Woodcraft clip-ons yesterday (Sat 15th August), they should arrive by Tues/Weds of next week and I hope to have them installed on next Sunday (30th). Will try to remember to take pics of install process and post the relevant ones as soon as practicable.

Wish me luck, I ain't the most mechanical of people, I hope the instructions are pretty much idiot proof!

[kkim]

Worked for this idiot!

[Lukey]

Thanks to you kkim I've received my set of woodies for my ninja 09. Really appreciated your detailed write up which answered pretty much all of my questions regarding this mod. need to get around to installing however - having a bit of trouble with the bar ends! anyway i'm hoping they provide me with much more attack on the seat and will also look at lower the front forks to pronounce this change more so! If these bikes came like this stock they would be perfect, well for me at least! thanks again - you've been a huge help!

[kkim]

are you heating the bar end screws with a torch?

[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?

[NJD022588]

Take out your stripped bolt and buy a new one. Most hardware stores have something that will measure the pitch and diameter of a bolt.

I have a hard time finding a hardware store here that has a good selection of metric bolts, but I'm sure you wont have that problem.

[JaeL]

I'm in the middle of this install the moment... thanx again kkim

[250rinblack]

Installed my Woodcraft clip-ons today

Not being the most mechanical of people I enlisted the help of a friend who has mechanical experience with both cars and bikes. It helps a lot to have to the rights tools (well most of them anyway) to get the job done, and saves a lot of time.

The hardest part of course was getting the screws out of the end of the old bars. Not having a torch or any sort of heating implement, we drilled them out. Using 4mm, then 6mm then 10mm bits to get them out, as no amount of using pliers of any description would move them.

[250rinblack]

The rest of the install was pretty straight forward, the grips proving difficult until we blew them off with the air compressor. We had the lap-top open at this thread to help with the bits that the written instructions didn't go into too much detail with, and it was a huge help. Especially the bit about the air-compressor, after trying for quite a while to pry off the grips with a small screwdriver.

[250rinblack]

All-in-all it took about 2 and three quarter hours to get everything installed, taking care not to crimp any fittings, doing the lock-to-lock check and making sure everything was tightened down correctly.

So a couple of pics showing the difference in the riding position, using my wrists and the ninja decal as a reference point you can see how much difference there is. The bike was in the same position and you can see from the background how much further down my shoulders and head are. Nothing in either picture had been moved so you've got some pretty good reference points.

I'm 177cm (5 feet 9 and a half inches) and 75kg (165 pounds) for those of you wondering about the size of organic material sitting on the bike....

[250rinblack]

After the install I rode the bike home, a trip of about 40km (25 miles). On a variety of city roads and speeds, varying from 60kh surbuban streets to 100kph freeways. None of it too taxing, but a good spread of the sort of stuff I ride on most days.

Although I am very much a novice, the difference was like night and day for me. The bike seemed to be much easier to corner, and "flickability" was much improved. I felt the bike was much more responsive. Now it could just be my lack of experience and also the euphoria of having installed a new gizmo making me predisposed to being impressed, but that's how it seemed. I felt a lot more connected to the front end if that makes any sense. Kinda makes me wonder why Kawasaki didn't install something similar from the outset.

I also found the riding position comfortable, although it was only about a 25-30 minute ride home. I'm planning on a longer ride tomorrow, and I guess a decent length trip will soon tell the comfort story better.

So I've got my first mod up and running (the Yoshi pipe and single-seat cowl were done by the previous owner), and I'd just like to thank all of the other posters for their pictures and text, it makes the whole thing a much easier process.

Tomorrow the beach on the Gold Coast beckons...

[angrycrow]

just ordered mine off Richards site. cant wait for them to come in the mail cause all i do out here is ride downhill twisties . ahh im so anxious

[Locksmiff]

Originally Posted by 250rinblack

The bike was in the same position and you can see from the background how much further down my shoulders and head are. Nothing in either picture had been moved so you've got some pretty good reference points.

I'm 177cm (5 feet 9 and a half inches) and 75kg (165 pounds) for those of you wondering about the size of organic material sitting on the bike....

I noticed in the after picture that there is silver tubing showing, as if you have lowered the front.......have you lowered the front of the bike as well ???

[rockNroll]

Originally Posted by Locksmiff

I noticed in the after picture that there is silver tubing showing, as if you have lowered the front.......have you lowered the front of the bike as well ???

That's the top of the forks, they stick out above the top triple, but the stock bars cover them up. When you remove the stock bars, you see these.

[250rinblack]

Originally Posted by rockNroll

That's the top of the forks, they stick out above the top triple, but the stock bars cover them up. When you remove the stock bars, you see these.

This is the end result. Those unsightly screw holes have been filled and I'm looking for some rubber/plastic caps to fit over the tops of the forks to just tidy things up.

Took the bike for a much longer ride yesterday. Initial part was on a freeway, and I have to say that the new riding position is a big improvement in terms of buffeting at speed. Previously I found that at about 120kph my head was being pulled about a fair bit, now with it a bit lower my guess is that the fairing is pushing much of the airflow over the top of my helmet. 130kph felt quite comfortable.

The next part of the ride was up and down hill twisties, and I loved it , I just felt more confident cornering the bike without getting carried away with over enthusiasm. All in all I covered about 150km on all types of roads and the only minor problem was my shoulders tended to tense up a bit (which I think is more an experience issue than riding posture) but I learned to relax and that seemed to help.

Oh and the Ninja got paid a compliment. I was stopped at some roadworks, and so I asked the young guy with the Stopsign how long I'd be there. "Umm about five minutes" he said. Then he says:"Is that a 600?"
I told him the truth but it was great all the same

[rockNroll]

What did you fill the holes with? I put the bolts back in and ran em down so now there's four Allens there now. I also had to wipe that white paint outta there w/ some brake kleen. I was planning on getting four set screws later, to fill those holes.

[250rinblack]

I put the Allens back in while I search for something more appealing. I wasn't really sure about removing the white paint, I thought it could be of some importance to the bike mechanics when I get it serviced. If it's not required then it goes too.

[NJD022588]

Use the allen bolts for a GPS mount.

http://www.ninjette.org/forums/showthread.php?t=27497

[gizmogamez]

Originally Posted by NJD022588

Use the allen bolts for a GPS mount.

http://www.ninjette.org/forums/showthread.php?t=27497

That was my thought exactily!
I was thinking about making a mount for there before but was lazy since the handle would then need longer bolts and it might be weird, but since a mount would cover all that stuff it would be perfict now.

[zev42]

After 2 (looonnnggg) weeks of waiting, my clip-ons should be here today! Whooo!!!! I'm still debating if I want to install them myself, or have a local shop do it for me. I'm afraid I might mess something up due to over-excitement.

[Ken]

Originally Posted by zev42

After 2 (looonnnggg) weeks of waiting, my clip-ons should be here today! Whooo!!!! I'm still debating if I want to install them myself, or have a local shop do it for me. I'm afraid I might mess something up due to over-excitement.

Michelle it's definitely an easy DIY job. Just make sure you have a drill to make an alignment hole and a handheld torch to heat up the bar-end screws and follow Kelly's instructions and it'll be a piece of cake.

[zev42]

Well, it's definitely a reach! Being 5'1", the reach is more than I had anticipated. It seems to be better at turns, but I'll have to take the bike out for another test run. I only took it out on the street for a little bit, and since all the local canyons are on fire (ACH, GMR, Azusa...) I couldn't fully test it out.

Well hopefully the fires will die down soon, and I can really test out how these clip-ons are with tight turns and some knee dragging!

Next step: Get a pair of Pazzo levers. My stock levers are very uncomfortable, and really need to be adjustable for my tiny hands.

[rockNroll]

Originally Posted by zev42

Well, it's definitely a reach! Being 5'1", the reach is more than I had anticipated. It seems to be better at turns, but I'll have to take the bike out for another test run. I only took it out on the street for a little bit, and since all the local canyons are on fire (ACH, GMR, Azusa...) I couldn't fully test it out.

Well hopefully the fires will die down soon, and I can really test out how these clip-ons are with tight turns and some knee dragging!

Next step: Get a pair of Pazzo levers. My stock levers are very uncomfortable, and really need to be adjustable for my tiny hands.

Do you have rear sets?

[250rinblack]

Originally Posted by zev42

Well, it's definitely a reach! Being 5'1", the reach is more than I had anticipated. It seems to be better at turns, but I'll have to take the bike out for another test run. I only took it out on the street for a little bit, and since all the local canyons are on fire (ACH, GMR, Azusa...) I couldn't fully test it out.

Hi Michelle, can I make a suggestion re the test ride? When I installed mine the first serious test ride I took involved a lengthy ride on a local freeway. I did this to just accustomise myself to the new riding postion, get myself sorted before I went on any twisty stuff. After having worked out how it affected me in those conditions i.e rider comfort, head position (including over the shoulder checks etc) I then peeled off the freeway and went onto my favourite bit of twisty road. You will instantly notice the difference, you're more over the front wheel and I found the bike was much more receptive to my shifting weight (not that it wasn't good before, it just seems even better now), it just seems so much more "flickable".

All of that said, as the friend who helped with the install (who is also a rider, Ducati 999s) gave me some sound advice: Don't push it initially, work your way into things. I think what he meant was that it's very easy to become enthralled with your lastest mod, and push things when perhaps easing into it might be a slightly better option.

That said, I love this modification and it just makes a good bike even better.

[zev42]

Originally Posted by rockNroll

Do you have rear sets?

Yep.

[rockNroll]

Originally Posted by zev42

Yep.

Okay then.... your next step can be the adjustable levers

[zev42]

You're right, I probably should get more used to the new position. I also should get the Pazzo adjustable levers so it's easier to pull the clutch in :-D Somehow, after the installation of the clip-ons, my clutch lever is 1 inch further away than it was. No clue how or why, but it sure makes it difficult.

[kkim]

did you or a shop install them?

[Locksmiff]

Does this mod screw with factory cable lengths in the clutch and accellorator (<---- I know thats spelt wrong)

[kkim]

Originally Posted by Locksmiff

Does this mod screw with factory cable lengths in the clutch and accellorator (<---- I know thats spelt wrong)

no

[CRXTrek]

Originally Posted by Locksmiff

Does this mod screw with factory cable lengths in the clutch and accellorator (<---- I know thats spelt wrong)

No adjusting needed Woodcraft made a great product. Only hard part of the install is drilling the loacating holes for the switches.

[250rinblack]

Originally Posted by CRXTrek

No adjusting needed Woodcraft made a great product. Only hard part of the install is drilling the loacating holes for the switches.

I would add to that: getting the screws out of the bar-ends can be difficult if you don't have the right tools. Heating them up seems to be the most civilised way of removing them, we drilled mine and I'm not a big fan of drilling things (or any use of brute force) when there's another option. Take your time, read and then re-read this thread and just make sure when you're finished to do your clearance checks and make sure nothing is fouling and finally tighten everything up.

It's all good

[zev42]

I accidentally stripped the bolt while adjusting my clip-ons, so now my clip-ons are (at the moment) permanently stuck in a position I don't like.... any advice?

[kkim]

Originally Posted by zev42

I accidentally stripped the bolt while adjusting my clip-ons, so now my clip-ons are (at the moment) permanently stuck in a position I don't like.... any advice?

one of the allen bolts?

[zev42]

Yep, one of the allen bolts.

[kkim]

try loosening up all the other bolts that hold that clamp on and see if that will allow you enough room to grab the stripped Allen with a vise grips to loosen it. If not, you'll need to drill off the head of the stripped bolt with a drill bit. Be careful if you do that to not hit the clamp.

[zev42]

I'll try that when I get home, thanks!

[rockNroll]

You could loosen the two bolts on the other side and rotate, leave the stripped bolt be. (Yeah the inside two are a hassle, but you can do it).