DIY -Weighted Bar Ends for Clipons for FREE!!! (almost)

kkim · February 28th, 2009, 09:33 PM

In my search to get rid of the wobbles I've been experiencing on the front end of my bike, one of the possible causes I've researched could be the non weighted bar ends of the Woodcraft clipons I installed recently. So, I went searching for a universal type of bar end, but what I was finding were very light weight aluminum types that weren't very weighty.

If only I could find some that were the same weight as the stock bar ends that would be great!!! Hey... wait a minute....

I knew I had seen the mounting method used in the universal type bar ends before... they are the same that is used on my dirt bike "bark busters". I could use the same technique to mount my stock bar ends to the clip on tubes!!

Okay, first step is to remove the plastic end caps from the Woodcraft clipons. I used an adjustable pliers (most likely older than most of us on the board) to work the cap off. Just grab it and twist and twist and twist. It will eventually come out.

Once that's off, it's time to prepare the bar end. You will need the stock bar end and a slightly longer bolt that the stock setup uses. I ended up with a 2 1/2" countersunk head allen 5/16" bolt found at the hardware store. I wanted to use a metric bolt, but they didn't have any long enough. Also a metric washer the will fit over the 5/16" bolt and also fit into the clipon tube. A piece of fuel line that will slip over the bolt and still fit inside the clipon tube and a 5/16" nut.

Stick the bolt through the stock bar end weight...

then stick the washer on the bolt

Measure out and cut the fuel line so that it leaves enough space on the end of the bolt after it is slipped onto the bolt. when done, this is what you are left with.

Tighten the nut down to the fuel line till it is snug, then insert the assembled part into the clipon tube.

Tighten the bolt with the allen wrench. As the bolt turns, it also turns the nut, but the nut gets caught on the fuel line and starts to be tightened on the bolt. As the nut is drawn in, it expands the rubber fuel line inside the tube and pushes it out against the inside of the tube, securing the bar end to the tube. Keep tightening the allen bolt until the bar end is solid on the clipon tube.

Do this to both sides and when completed, you will have weighted bar ends for your clipons for free... (or the cost of some bolts, washers and nuts.

)

miks · February 28th, 2009, 09:39 PM

Great DIY.

Has this fixed the front end wobble problem?

kkim · February 28th, 2009, 09:42 PM

just did this a few minutes ago. It's way too windy (50mph gusts) to be out right now.

miks · February 28th, 2009, 09:49 PM

I've always thought that Hawaii had beautiful weather 24/7

Well I do hope this cures the front end wobbling problem. All the best!

kkim · February 28th, 2009, 09:51 PM

Thanks, but somehow my guess is that it's another related item and this won't stop it. I was looking for a way to weight the bars anyway.

miks · February 28th, 2009, 09:54 PM

Weld some 10kg dumbbells on each side

Ninja007 · February 28th, 2009, 11:31 PM

wow kkim! I'm pretty impressed. you're pretty innovative! this is great info and a great DIY! I'll have to remember this for when I get my woodstock clip-ons! cheers!

Shift250R · March 25th, 2009, 06:12 AM

Kelly, did you use a specific type/size of fuel line or can I just ask for some at an autoparts store? I bought a bar ends kit but the rubber end is too big for the hole in the clipon.

Syphen · March 25th, 2009, 11:07 AM

would a generic steering dampener not work? a company probably makes one by now.

kkim · March 25th, 2009, 11:20 AM

Quote:

Originally Posted by Shift250R

Kelly, did you use a specific type/size of fuel line or can I just ask for some at an autoparts store? I bought a bar ends kit but the rubber end is too big for the hole in the clipon.

sorry... I had a piece of fuel line lying around and it fit the bolt and the clipon tube size. I didn't bother looking at what size fuel line it was.

Just measure the clipon hole size and go look for some fuel line with that OD or a bit smaller.

kkim · March 25th, 2009, 11:21 AM

Quote:

Originally Posted by Syphen

would a generic steering dampener not work? a company probably makes one by now.

dunno... this was easy and cheap.

randomwalk101 · March 25th, 2009, 11:36 AM

Holy barend batman...

Shift250R · March 25th, 2009, 12:08 PM

Quote:

Originally Posted by kkim

sorry... I had a piece of fuel line lying around and it fit the bolt and the clipon tube size. I didn't bother looking at what size fuel line it was.

Just measure the clipon hole size and go look for some fuel line with that OD or a bit smaller.

I went to an auto store and bought some 5/16 size fuel line and it works! Just in case anyone else needs to know. Thanks Kelly for the idea

the bike feels alot smoother with the bar ends.

kkim · March 25th, 2009, 12:17 PM

Glad it worked.

HKr1 · March 25th, 2009, 01:17 PM

Pretty slick diy

kkim · March 25th, 2009, 01:23 PM

lol... us old farts are cheap bastids! ...oh, wait, look who I'm talking to.

besides, I wanted a way to check if maybe my wobbling problem was due to the unweighted clipons and this was the simplest, easiest way I could find to get some bar ends with some heft to them to test the theory.

unfortunately they didn't help, but they do help to reduce vibrations, so it wasn't a total loss.

DmbShn41 · March 25th, 2009, 03:46 PM

Totally stupid question from a n00b(not me, some random guy sitting next to me):

What do clip-ons do, what exactly are they? Just an aftermarket set of handgrips?

And

The weight on the bar ends will help reduce vibrations from suspension/road? Could you increase the stock weighted bar ends?

kkim · March 25th, 2009, 04:17 PM

http://www.ninjette.org/forums/showthread.php?t=11365

increased weight dampens vibrations and yes, you can increase the weight of the bar ends, if you can find any heavier than what is on there stock.

DmbShn41 · March 25th, 2009, 04:36 PM

I can make them as heavy as I want. I have access to a machine shop filled to brim with material and equipment. What I worry about is how heavy is too heavy. Obviously if I put weights on there that measure 6 inches beyond the tube, of 316L Sanitary stainless steel, 1.5 round, then that is adding around a couple pounds to each side...too much?

kkim · March 25th, 2009, 04:53 PM

dunno, but a guess would be, yes, that's too much. experiment and let us know what works best.

paterick4o8 · June 19th, 2009, 05:23 PM

idk how I missed this DIY, but I'm glad I found it.
Just what I was looking for!!!! thanks Kelly

SCREEM · June 19th, 2009, 05:45 PM

did this as well, great mod

paterick4o8 · June 20th, 2009, 08:48 AM

Quote:

Originally Posted by kkim

In my search to get rid of the wobbles I've been experiencing on the front end of my bike, one of the possible causes I've researched could be the non weighted bar ends of the Woodcraft clipons I installed recently.

Kkim.. I know you've said you had front end wobbles.. when exactly did/do you get them? when in the middle of a turn? going on a straightaway riding normally?

kkim · June 20th, 2009, 10:20 AM

http://www.ninjette.org/forums/showt...hlight=wobbles

still have them.

maxwellca21 · February 17th, 2011, 02:56 PM

kkim,

i got the woodcraft clip-ons installed thanks to your awesome DIY thread. now Im trying to do this bar ends DIY but im having trouble finding the bolt so that specific size. I went to Home depot and lowes and spent an hour there and still cant find it. found out later from the people that there that they dont have it for sure. so now im all bummed out

anyone know where i can get these bolts around san diego area? i would try kragens and pepboy next.

kkim · February 17th, 2011, 03:09 PM

I bought mine from a local Ace Hardware store.

Cuongism · February 17th, 2011, 06:00 PM

+1 for Ace, they have more bolts/nuts than any store. I got mine there as well for the clipons (at the Pacific Beach Ace, but I'm sure there's one closer to you). I also think I have extra hosing if you need it.

kkim · February 17th, 2011, 06:44 PM

For some reason, the local Ace has a lot of metric hardware that the other stores don't carry, too. It's not cheap, but when you need a couple of specific bolts, there's no better place to go around here than Ace.

maxwellca21 · February 18th, 2011, 06:56 AM

Quote:

Originally Posted by kkim

I bought mine from a local Ace Hardware store.

Quote:

Originally Posted by Cuongism

+1 for Ace, they have more bolts/nuts than any store. I got mine there as well for the clipons (at the Pacific Beach Ace, but I'm sure there's one closer to you). I also think I have extra hosing if you need it.

Ace hardware...here i come! thanks guys for the fast reply!

CZroe · February 18th, 2011, 10:03 AM

Quote:

Originally Posted by maxwellca21

kkim,

i got the woodcraft clip-ons installed thanks to your awesome DIY thread. now Im trying to do this bar ends DIY but im having trouble finding the bolt so that specific size. I went to Home depot and lowes and spent an hour there and still cant find it. found out later from the people that there that they dont have it for sure. so now im all bummed out

anyone know where i can get these bolts around san diego area? i would try kragens and pepboy next.

It's O'Reilly now.

tac12345 · March 6th, 2011, 03:01 PM

What kind of aftermarket bar end would fit ? i'm checking on ebay, some have metric size, other have SAE...

http://cgi.ebay.ca/NEW-UNIVERSAL-7-8...ht_1903wt_1739

http://cgi.ebay.ca/BEA-SI-CNC-Alumin...#ht_2599wt_905

wellcraft · March 6th, 2011, 06:23 PM

I did this DIY today and it really works. I was able to find the screws and nuts at my local Lowes. Picked up some stainless steel screws and bolts.

maxwellca21 · March 7th, 2011, 02:34 AM

Quote:

Originally Posted by wellcraft

I did this DIY today and it really works. I was able to find the screws and nuts at my local Lowes. Picked up some stainless steel screws and bolts.

i did this DIY too! awesome result...got everything at ACE hardware.

dragonboy · July 29th, 2011, 06:42 PM

No luck at Ace and had to settle for silver crosshead bolts at OSH but worked the same. Thanks again Kelly!!!

Vampyre · July 29th, 2011, 06:59 PM

I had no luck at Ace, but will go to Lowes tomorrow.

Alex · September 26th, 2011, 11:34 PM

All pics in first post replaced. Big thanks to Paul for finding them, recreating them, and cataloging them.

headshrink · September 27th, 2011, 12:10 AM

An even better solution, albeit a bit pricey.

February 28th, 2009, 09:33 PM	#1
kkim Join Date: Nov 2008 Posts: Too much.	DIY -Weighted Bar Ends for Clipons for FREE!!! (almost) In my search to get rid of the wobbles I've been experiencing on the front end of my bike, one of the possible causes I've researched could be the non weighted bar ends of the Woodcraft clipons I installed recently. So, I went searching for a universal type of bar end, but what I was finding were very light weight aluminum types that weren't very weighty. If only I could find some that were the same weight as the stock bar ends that would be great!!! Hey... wait a minute.... I knew I had seen the mounting method used in the universal type bar ends before... they are the same that is used on my dirt bike "bark busters". I could use the same technique to mount my stock bar ends to the clip on tubes!! Okay, first step is to remove the plastic end caps from the Woodcraft clipons. I used an adjustable pliers (most likely older than most of us on the board) to work the cap off. Just grab it and twist and twist and twist. It will eventually come out. Once that's off, it's time to prepare the bar end. You will need the stock bar end and a slightly longer bolt that the stock setup uses. I ended up with a 2 1/2" countersunk head allen 5/16" bolt found at the hardware store. I wanted to use a metric bolt, but they didn't have any long enough. Also a metric washer the will fit over the 5/16" bolt and also fit into the clipon tube. A piece of fuel line that will slip over the bolt and still fit inside the clipon tube and a 5/16" nut. Stick the bolt through the stock bar end weight... then stick the washer on the bolt Measure out and cut the fuel line so that it leaves enough space on the end of the bolt after it is slipped onto the bolt. when done, this is what you are left with. Tighten the nut down to the fuel line till it is snug, then insert the assembled part into the clipon tube. Tighten the bolt with the allen wrench. As the bolt turns, it also turns the nut, but the nut gets caught on the fuel line and starts to be tightened on the bolt. As the nut is drawn in, it expands the rubber fuel line inside the tube and pushes it out against the inside of the tube, securing the bar end to the tube. Keep tightening the allen bolt until the bar end is solid on the clipon tube. Do this to both sides and when completed, you will have weighted bar ends for your clipons for free... (or the cost of some bolts, washers and nuts. )

February 28th, 2009, 09:39 PM	#2
miks I'm lovin' it. Name: Mike Location: Melb, Australia Join Date: Feb 2009 Motorcycle(s): '09 Black 250R Posts: A lot.	Great DIY. Has this fixed the front end wobble problem? __________________________________________________ Son: When I grow up I want to ride a motorbike. Father: You can't do both son.

February 28th, 2009, 09:49 PM	#4
miks I'm lovin' it. Name: Mike Location: Melb, Australia Join Date: Feb 2009 Motorcycle(s): '09 Black 250R Posts: A lot.	I've always thought that Hawaii had beautiful weather 24/7 Well I do hope this cures the front end wobbling problem. All the best! __________________________________________________ Son: When I grow up I want to ride a motorbike. Father: You can't do both son.

February 28th, 2009, 09:54 PM	#6
miks I'm lovin' it. Name: Mike Location: Melb, Australia Join Date: Feb 2009 Motorcycle(s): '09 Black 250R Posts: A lot.	Weld some 10kg dumbbells on each side __________________________________________________ Son: When I grow up I want to ride a motorbike. Father: You can't do both son.

March 25th, 2009, 03:46 PM	#17
DmbShn41 Wannabe Reborn Name: Unregistered Location: Cincy Ohio Join Date: Mar 2009 Motorcycle(s): Blue 2008 Ninja 250 Posts: 302	Totally stupid question from a n00b(not me, some random guy sitting next to me): What do clip-ons do, what exactly are they? Just an aftermarket set of handgrips? And The weight on the bar ends will help reduce vibrations from suspension/road? Could you increase the stock weighted bar ends? __________________________________________________ " If you're here to show off and prove that your crotch rocket is faster than my Harley, you can leave now. "

February 28th, 2009, 09:42 PM	#3
kkim Join Date: Nov 2008 Posts: Too much.	just did this a few minutes ago. It's way too windy (50mph gusts) to be out right now.

February 28th, 2009, 09:51 PM	#5
kkim Join Date: Nov 2008 Posts: Too much.	Thanks, but somehow my guess is that it's another related item and this won't stop it. I was looking for a way to weight the bars anyway.

February 28th, 2009, 11:31 PM	#7
Ninja007 忍者 Name: Jake Location: WA Join Date: Dec 2008 Motorcycle(s): None Now - Used to have an '08 Ninja 250R Candy Blue Posts: 151	wow kkim! I'm pretty impressed. you're pretty innovative! this is great info and a great DIY! I'll have to remember this for when I get my woodstock clip-ons! cheers!

March 25th, 2009, 06:12 AM	#8
Shift250R ninjette.org member Name: Michael Location: Texas Join Date: Feb 2009 Motorcycle(s): 08 Ninja 250R Posts: 112	Kelly, did you use a specific type/size of fuel line or can I just ask for some at an autoparts store? I bought a bar ends kit but the rubber end is too big for the hole in the clipon.

March 25th, 2009, 11:07 AM	#9
Syphen Some weird Canuck! Name: Greg Location: Ontario - Canada Join Date: Dec 2008 Motorcycle(s): '92 CBR250RR "Babyblade", 2008 Ninja 250R, 2001 CBR600F4i Posts: 209	would a generic steering dampener not work? a company probably makes one by now.

March 25th, 2009, 11:36 AM	#12
randomwalk101 self wrencher Name: john Location: houston Join Date: Dec 2008 Motorcycle(s): 08 250r and 07 600r Posts: A lot.	Holy barend batman...

March 25th, 2009, 12:17 PM	#14
kkim Join Date: Nov 2008 Posts: Too much.	Glad it worked.

March 25th, 2009, 01:17 PM	#15
HKr1 IC2(SW) Name: Kerry Location: Pensacola Join Date: Nov 2008 Motorcycle(s): . Posts: A lot.	Pretty slick diy

March 25th, 2009, 01:23 PM	#16
kkim Join Date: Nov 2008 Posts: Too much.	lol... us old farts are cheap bastids! ...oh, wait, look who I'm talking to. besides, I wanted a way to check if maybe my wobbling problem was due to the unweighted clipons and this was the simplest, easiest way I could find to get some bar ends with some heft to them to test the theory. unfortunately they didn't help, but they do help to reduce vibrations, so it wasn't a total loss.

March 25th, 2009, 04:17 PM	#18
kkim Join Date: Nov 2008 Posts: Too much.	http://www.ninjette.org/forums/showthread.php?t=11365 increased weight dampens vibrations and yes, you can increase the weight of the bar ends, if you can find any heavier than what is on there stock.

March 25th, 2009, 04:36 PM	#19
DmbShn41 Wannabe Reborn Name: Unregistered Location: Cincy Ohio Join Date: Mar 2009 Motorcycle(s): Blue 2008 Ninja 250 Posts: 302	I can make them as heavy as I want. I have access to a machine shop filled to brim with material and equipment. What I worry about is how heavy is too heavy. Obviously if I put weights on there that measure 6 inches beyond the tube, of 316L Sanitary stainless steel, 1.5 round, then that is adding around a couple pounds to each side...too much? __________________________________________________ " If you're here to show off and prove that your crotch rocket is faster than my Harley, you can leave now. "

March 25th, 2009, 04:53 PM	#20
kkim Join Date: Nov 2008 Posts: Too much.	dunno, but a guess would be, yes, that's too much. experiment and let us know what works best.

June 19th, 2009, 05:23 PM	#21
paterick4o8 ninjette.org sage Name: patricK Location: San Jose, CA--BAY AREA! Join Date: Mar 2009 Motorcycle(s): '08 blue 250R [sold]. '09 lime ZX-6R [stolen :( ]. '06 blue 636. Posts: 918	idk how I missed this DIY, but I'm glad I found it. Just what I was looking for!!!! thanks Kelly

June 19th, 2009, 05:45 PM	#22
SCREEM ninjette.org member Name: Marc Location: Montreal Join Date: Jun 2009 Motorcycle(s): 09 250R, 08 connie 14, 08 honda ruckus(gave to mom) Posts: 92	did this as well, great mod

June 20th, 2009, 10:20 AM	#24
kkim Join Date: Nov 2008 Posts: Too much.	http://www.ninjette.org/forums/showt...hlight=wobbles still have them.

February 17th, 2011, 02:56 PM	#25
maxwellca21 ninjette.org member Name: Max Location: san marcos Join Date: Oct 2010 Motorcycle(s): 09 ninja 250 Posts: 131	kkim, i got the woodcraft clip-ons installed thanks to your awesome DIY thread. now Im trying to do this bar ends DIY but im having trouble finding the bolt so that specific size. I went to Home depot and lowes and spent an hour there and still cant find it. found out later from the people that there that they dont have it for sure. so now im all bummed out anyone know where i can get these bolts around san diego area? i would try kragens and pepboy next. __________________________________________________ ride it like you stole it!

February 17th, 2011, 03:09 PM	#26
kkim Join Date: Nov 2008 Posts: Too much.	I bought mine from a local Ace Hardware store.

February 17th, 2011, 06:00 PM	#27
Cuongism ninjette.org certified postwhore Name: Cuong Location: San Diego Join Date: Jul 2010 Motorcycle(s): 2008 Ninja 250r, 2007 Daytona 675 Posts: A lot.	+1 for Ace, they have more bolts/nuts than any store. I got mine there as well for the clipons (at the Pacific Beach Ace, but I'm sure there's one closer to you). I also think I have extra hosing if you need it.

February 17th, 2011, 06:44 PM	#28
kkim Join Date: Nov 2008 Posts: Too much.	For some reason, the local Ace has a lot of metric hardware that the other stores don't carry, too. It's not cheap, but when you need a couple of specific bolts, there's no better place to go around here than Ace.

March 6th, 2011, 03:01 PM	#31
tac12345 ninjette.org member Name: Alexandre Location: Montreal Join Date: Jul 2009 Motorcycle(s): Ninja 250r 09 SE Posts: 172	What kind of aftermarket bar end would fit ? i'm checking on ebay, some have metric size, other have SAE... http://cgi.ebay.ca/NEW-UNIVERSAL-7-8...ht_1903wt_1739 http://cgi.ebay.ca/BEA-SI-CNC-Alumin...#ht_2599wt_905

March 6th, 2011, 06:23 PM	#32
wellcraft ninjette.org guru Name: JR Location: Augusta, GA Join Date: Dec 2009 Motorcycle(s): Ninja 250R Posts: 432	I did this DIY today and it really works. I was able to find the screws and nuts at my local Lowes. Picked up some stainless steel screws and bolts.

July 29th, 2011, 06:42 PM	#34
dragonboy ninjette.org member Name: JT Location: NorCal Join Date: May 2011 Motorcycle(s): 2010 250R SE Green Machine, 2011 250R SE White Lightning Posts: 155	No luck at Ace and had to settle for silver crosshead bolts at OSH but worked the same. Thanks again Kelly!!!

July 29th, 2011, 06:59 PM	#35
Vampyre ninjette.org sage Name: Joseph Location: Winter Park, FL Join Date: May 2011 Motorcycle(s): 2011 250R Black, 2005 ZX-6R Blue Posts: 623	I had no luck at Ace, but will go to Lowes tomorrow.

September 26th, 2011, 11:34 PM	#36
Alex ninjette.org dude Name: 1 guess :-) Location: SF Bay Area Join Date: Jun 2008 Motorcycle(s): '13 Ninja 300 (white, the fastest color!), '13 R1200RT, '14 CRF250L, '12 TT-R125LE Posts: Too much. Blog Entries: 7	All pics in first post replaced. Big thanks to Paul for finding them, recreating them, and cataloging them. __________________________________________________ Montgomery Street Motorcycle Club / cal24.com / crf250l.org / ninjette.org ninjette.org Terms of Service Shopping for motorcycle parts or equipment? Come here first. The friendliest Ninja 250R/300/400 forum on the internet! (especially Unregistered)

September 27th, 2011, 12:10 AM	#37
headshrink ninjette.org certified postwhore Name: Bob Location: CA Join Date: Dec 2008 Motorcycle(s): '08 Ninja 250r, '14 CBR500r Posts: A lot.	An even better solution, albeit a bit pricey. __________________________________________________ Honda Interceptor VFR800 DLX (2014, 8th gen) Honda CBR500r (2014) - FOR SALE Kawi Ninja 250r (2008) - Restored and passed-down within family, only to be abandoned

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