Post clubman install complications

Nduetime

New Member
So I spent some time tonight installing my clubman bars on my KZ400 D3. Much happier with the appearance and feel compared to the stock bars. I started noticing some issues that need to be address at every step of the install. Looking for a little advise, words of wisdom, suggestions, or anything else you want to hurl my way.

One the issues that I'm encountering would be the dreaded hose length. This was something I was aware of prior to my install but I'm a little stumped with the way to resolve it. As you can see in the photo below, the brake hose exits the master cylinder at exactly the same height as the headlight bracket.

IMG_1263.jpg


As of now, I can either run it below or above the bracket but the hose still needs to be replaced with a new, smaller length hose. I'm still up in the air in terms of a replacement but I'm kind of leaning towards the Goodridge Sniper 2 hose and fittings. Of course, they're a bit more costly but they also function (fully) with tight bends according to this guy.

http://youtu.be/MPU6YNy3MMs.

Regardless of which hose I choose, I would assume I'd need something like this to help clear the headlight bracket, no?

black-goodridge-sniper-2-micro-line-90-degree-banjo-fitting-4.jpg


Additionally, the master cylinder interferes with those massive turn signals.

IMG_1262.jpg


Since I'm still learning to ride, I'm sticking with signals (no need adding more stress to this learning experience.) Need to figure out a solution for that. I was thinking of something that would create a "S" bend to allow me to use the existing turn signals but drop their current location, allowing for clearance from the master cylinder. I suppose the easier solution would be some universal fork-mounts where I can set them to the ideal height? However, I believe that would require the removal of the existing bracket which, I'm not sure I want to tackle right now.

Lastly, I need to figure out a way to address my lack of room for my kill switch. The stock control is too large to fit with the brake and throttle tube.
 
Take your headlight mounts (that the signals mount to) and flip them left and right, and upside down. It will angle your headlight away from the forks more and a lower position, and "might" give you the clearance you need.

Search eBay for "custom brake lines" or something similar. There's a guy up in Canada that will make a braided brake line in the length / color you want with whatever fittings you need. Last one I bought was about $40 shipped?
 
I don't remember seeing that the mounts are removable. I'll take a closer look in the morning because that just doesn't sound right. Thanks for the eBay heads up. Do you thing the 90 degree banjo straight off the master cylinder is the way to go? My thought is that by doing so, the hose would be heading I'm the proper direction. I'll take some better pictures of this tomorrow to better explain my reasoning.
 
big rich is on the right path there, you'll need to take the top triple clamp off and then it should be easy enough to just slide the headlight mounts straight up the fork tubes and do the flip/side-swap thing.

while you're on ebay check these

http://www.ebay.com/sch/i.html?_trksid=p2050601.m570.l2632.R2.TR11.TRC1.A0.H0.Xheadlight+bracket&_nkw=headlight+bracket&_sacat=10063&_from=R40

all sorts of sizes and shapes from $10 for the dead basic ones that people have been using since the 60s and they mostly have holes to mount the indicators too,they allow you to put the headlight wherever you want it, right out of the way of m/cyl etc

while you're there check out all the different indicators and headlights too, you'll be there for hours, really easy way to change up the look of your front end, make it look much neater

have fun
cheers spotty
 
yeah... I did a little research after I posted last. Gotta love the part diagrams available online. Gonna give it a shot this morning.
 
clubman's are a horrible bar for learning to ride
you have less control over the bike and may never learn good skills with them
do yourself a huge favor,ditch those stupid things and put some standard bars on so you can learn to ride properly
 
So I managed to flip the headlight brackets. That certainly lowered the headlight and created a bit more room for the brake hose. However, in doing so, I ran into another problem. The headlight won't fit properly due to clearance issues. It only fits upside down now and is also limited by the three way joint for the brakes.

IMG_1265.jpg


I'm just going to pony up and get some universal brackets. Would I need to shave the brackets from the existing fork covers/purchase replacement fork covers without brackets?

Because I'm always interested in learning new things, xb33bsa, can you tell me what bad skills are developed when riding with clubmans? Are you talking about zombie armed posture?
 
Nduetime said:
I'm just going to pony up and get some universal brackets. Would I need to shave the brackets from the existing fork covers/purchase replacement fork covers without brackets?

Shave what brackets? If you get universal headlight mounts, they simply replace the stock ones.
 
+1 on xb33bsa's comment about riding position. It is a lot easier to learn good skills in a more neutral riding position that helps locate your weight more in the middle of the bike. Otherwise, you kind of have to learn to intentionally put your weight where you need it, not really a beginner skill IMO. Maybe start out with some "super bike" style bars which are lower, but a lot more like the stock bars compared to clip-ons or clubmans. Plus, you may be able to postpone the cable length issues as the change is not so extreme. I have old (70's) bikes with stock bars, clip-ons, and in between, and I personally feel a lot busier riding the clip on bike (RD350 Yamaha). I have very low bars in the stock stanchions (not clubmans) on my 400F Honda, and it is a lot friendlier to drive fast.

Otherwise, the universal brackets should work fine for you. Regardless, take care to have a really proper line to replace the long stocker. If there is a single thing that really needs to work when you need it most, its gotta be the front brake!
 
Nduetime said:
So I managed to flip the headlight brackets. That certainly lowered the headlight and created a bit more room for the brake hose. However, in doing so, I ran into another problem. The headlight won't fit properly due to clearance issues. It only fits upside down now and is also limited by the three way joint for the brakes.

IMG_1265.jpg


I'm just going to pony up and get some universal brackets. Would I need to shave the brackets from the existing fork covers/purchase replacement fork covers without brackets?

Because I'm always interested in learning new things, xb33bsa, can you tell me what bad skills are developed when riding with clubmans? Are you talking about zombie armed posture?
-

zombie arm i love that !! yes
what it boils down to is upper body and arm position you must have bent elbows to learn riding properly and to have full control. period
clubmans and clip ons put the rider in a racing crouch which is ok for the racetrack or carving turns but it sucks for general riding in and around traffic to be in a racers crouch
what happens is the rider sits up and reaches down to the bars
really a terrible way for anybody to ride but even worse for a learner
it also important to learn riding standing on the pegs as well
that and proper positioning with elbows up and bent is the only way to learn proper skills
if you are reaching down to the bars with arms nearly locked straight (or up real high like the idiots with apes) you do not have full control of the machine even if you are a good rider it puts you at a disadvantage
 
aaaaaaaaaaand, if you're leaning down/forward to hold onto clip-ons/clubmans it pretty much determines that your face (and therefore eyes) is pointing at the front guard.....not ideal.
to overcome this (and see whats happeining on the road in front of you) you then have to tilt your head back so you're looking ahead and you WILL end up with a very sore neck
i know this to be true as i did this very thing on my XS250 and also my CB750, ended up putting the stock bars back on both of them
BUT never say never....give it a go, its all a learning curve thing
 
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