clip ons fitment

yantheman · 03-06-2010, 12:47 PM

Hi all, think I ask this before everyone disappears from the forum to the WDW

I bought a set of clip ons to replace the handle bar and they have no holes on them. How do I fit the control clusters on the left and right? They came off a Monster 900ie and sure the switches would be similar if not the same. I asked the previous owner and he told me he could not remember...

So I guess with the knowledgeable people on the forum can give me some help of how to fit the thing... I know I need to take off the top yoke and refit/reroute cables and hose etc etc.. but how do I go about in fitting the swtches? Do I drill the holes for the little plastic studs on the switches?

Thanks in advance

03-06-2010, 01:03 PM

i did.. when i fitted them to my last bike i lined them up to see wher ei wanted them and marked the nipple on the bar then drilled in...

yantheman · 03-06-2010, 01:07 PM

thanks for you reply, can I get away without drilling? previous owner didn't and how could he fix the throttle grip?

I guess if I can get away without drilling then I won't drill the holes.

03-06-2010, 01:47 PM

I haven't drilled any holes, just tighten up real good

yantheman · 03-06-2010, 02:04 PM

i see, thanks, next week I will try to fit them and see...

slob · 03-06-2010, 02:41 PM

I carefully removed the pegs from the switchgear and wrapped the bars in insulating tape until I achieved the desired interference fit.

yantheman · 03-06-2010, 02:48 PM

Thanks Rob! I was wondering how to fit the switches without the holes and if I cut the little tab, how would I stop the switches from merry-go-round!! Will do that next week. Thanks

03-06-2010, 03:20 PM

I transferred the holes for switch gear and throttle using original bars as template, worked out perfectly.

03-06-2010, 03:33 PM

I might use slob's idea as well.

How many pegs are there on each side?

yantheman · 03-06-2010, 03:40 PM

3 total, 1 on the left and 2 on the right. The left peg is on the front half of the indicator (+ Hi-lo beam). The second is on the top half of start/stop switch. The third is at the bottom of the throttle housing(this is metal infact)... all three are in different sizes as well!! Dremel is out

03-06-2010, 03:41 PM

I always cut the little tab off on both the switch & the throttle on my race bikes, if you just leave it & tighten it up it can crack the casting on the throttle.

03-06-2010, 04:02 PM

i always prefered to drill the holes simply cos its cheaper to replace the bars if you wanna go back to standard whereas i dont like the thought of the switches not being complete with lugs if i fitted the stock bars back on... (its just a perfectionist thing) they also save youhaving to tighten up the switches which can lead to overtightening and damaging of the switch or stripping of the thread inside the switch..

yantheman · 03-06-2010, 04:40 PM

Looks like its another scotoiler/no scotoiler thread!

Joking, don't hit me...

I think I am inclined to do the de-pegs method. Just that I had to replace my bent stock bar unfortunately the replacement bar came from a 900 carb (i think) and the holes were all over the place and I had to redrill all the holes and I misaligned one and the start/stop switch isn't quite where it should be and it cannot be adjusted.

So this time I want a slightly more flexible approach

Albie · 03-06-2010, 04:44 PM

Tell me this. Do the bars rotate in the clamps. I f they do then all you need is the dimension from the outside of stock bars and copy to the clipon bars if you want the anti rotate holes. Just undo the bar clamps and rotate until happy.

yantheman · 03-06-2010, 04:54 PM

Hi Albie, the bars on the clip ons are not moveable/rotateable. The square ends that you can see in the photo is part of the bar (all one part from machining). So I can't rotate the bar to adjust the switchgears.

03-06-2010, 12:47 PM	#1
yantheman Bronze Member Join Date: Dec 2007 Location: London Bike: M620sie Posts: 348	clip ons fitment Hi all, think I ask this before everyone disappears from the forum to the WDW I bought a set of clip ons to replace the handle bar and they have no holes on them. How do I fit the control clusters on the left and right? They came off a Monster 900ie and sure the switches would be similar if not the same. I asked the previous owner and he told me he could not remember... So I guess with the knowledgeable people on the forum can give me some help of how to fit the thing... I know I need to take off the top yoke and refit/reroute cables and hose etc etc.. but how do I go about in fitting the swtches? Do I drill the holes for the little plastic studs on the switches? Thanks in advance

03-06-2010, 04:44 PM	#14
Albie Fanactical volunteer Join Date: Oct 2003 Location: Kent Bike: M900 Posts: 9,033	Tell me this. Do the bars rotate in the clamps. I f they do then all you need is the dimension from the outside of stock bars and copy to the clipon bars if you want the anti rotate holes. Just undo the bar clamps and rotate until happy. __________________ http://albies93m900.blogspot.co.uk/

03-06-2010, 01:03 PM	#2
analogue_rogue Guest Posts: n/a	i did.. when i fitted them to my last bike i lined them up to see wher ei wanted them and marked the nipple on the bar then drilled in...

03-06-2010, 01:07 PM	#3
yantheman Bronze Member Join Date: Dec 2007 Location: London Bike: M620sie Posts: 348	thanks for you reply, can I get away without drilling? previous owner didn't and how could he fix the throttle grip? I guess if I can get away without drilling then I won't drill the holes.

03-06-2010, 01:47 PM	#4
rac3r Guest Posts: n/a	I haven't drilled any holes, just tighten up real good

03-06-2010, 02:04 PM	#5
yantheman Bronze Member Join Date: Dec 2007 Location: London Bike: M620sie Posts: 348	i see, thanks, next week I will try to fit them and see...

03-06-2010, 02:41 PM	#6
slob . Join Date: Jul 2003 Location: East London Bike: Multiple Monsters Posts: 9,714	I carefully removed the pegs from the switchgear and wrapped the bars in insulating tape until I achieved the desired interference fit.

03-06-2010, 02:48 PM	#7
yantheman Bronze Member Join Date: Dec 2007 Location: London Bike: M620sie Posts: 348	Thanks Rob! I was wondering how to fit the switches without the holes and if I cut the little tab, how would I stop the switches from merry-go-round!! Will do that next week. Thanks

03-06-2010, 03:20 PM	#8
simons Guest Posts: n/a	I transferred the holes for switch gear and throttle using original bars as template, worked out perfectly.

03-06-2010, 03:33 PM	#9
rac3r Guest Posts: n/a	I might use slob's idea as well. How many pegs are there on each side?

03-06-2010, 03:40 PM	#10
yantheman Bronze Member Join Date: Dec 2007 Location: London Bike: M620sie Posts: 348	3 total, 1 on the left and 2 on the right. The left peg is on the front half of the indicator (+ Hi-lo beam). The second is on the top half of start/stop switch. The third is at the bottom of the throttle housing(this is metal infact)... all three are in different sizes as well!! Dremel is out

03-06-2010, 03:41 PM	#11
Chass Guest Posts: n/a	I always cut the little tab off on both the switch & the throttle on my race bikes, if you just leave it & tighten it up it can crack the casting on the throttle.

03-06-2010, 04:02 PM	#12
analogue_rogue Guest Posts: n/a	i always prefered to drill the holes simply cos its cheaper to replace the bars if you wanna go back to standard whereas i dont like the thought of the switches not being complete with lugs if i fitted the stock bars back on... (its just a perfectionist thing) they also save youhaving to tighten up the switches which can lead to overtightening and damaging of the switch or stripping of the thread inside the switch..

03-06-2010, 04:40 PM	#13
yantheman Bronze Member Join Date: Dec 2007 Location: London Bike: M620sie Posts: 348	Looks like its another scotoiler/no scotoiler thread! Joking, don't hit me... I think I am inclined to do the de-pegs method. Just that I had to replace my bent stock bar unfortunately the replacement bar came from a 900 carb (i think) and the holes were all over the place and I had to redrill all the holes and I misaligned one and the start/stop switch isn't quite where it should be and it cannot be adjusted. So this time I want a slightly more flexible approach

03-06-2010, 04:54 PM	#15
yantheman Bronze Member Join Date: Dec 2007 Location: London Bike: M620sie Posts: 348	Hi Albie, the bars on the clip ons are not moveable/rotateable. The square ends that you can see in the photo is part of the bar (all one part from machining). So I can't rotate the bar to adjust the switchgears.