Tuning and modding » Handlebar replacements

Hi All,

I remember on the old forum there were quite a few threads on replacing the standards RS bars. I tried a search but couldn't find much on here. I already have risers and was going to try and move my cables to prepare for a handlebar option next. Well I followed the instructions on the Hornig website completely removing the side panels, clutch lever assembly and cables. I removed all the zip ties and rubber bands and tried to pull the clutch cable down through the frame but it was stuck. I then discovered a zip tie buried deep inside in between the frame and engine, radiator etc. I could barely feel it with a fingertip to confirm this was the culprit. After an hour of trying to reach or even see it clearly, I had to give up. I couldn't just get anything close to it to cut it without fear of cutting another wire in the bundle. I'm assuming this extra zip tie was something not encountered in others doing this mod. Has anyone else run into this? Is there a solution I'm not seeing?

Any feedback would be greatly appreciated!

I attacked it from below with a pair of long handled nail scissors.

At the old forum I was the one who did lower the handlebars 17 mm by milling them. If any interested...

Good luck with the ty-wrap )))

Zitat von Allan Redfox im Beitrag #4

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At the old forum I was the one who did lower the handlebars 17 mm by milling them. If any interested...

Good luck with the ty-wrap )))

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Well maybe when I get the energy again I'll take off the side panels and take another look but I saw no access to it from underneath to get a pair of diagonal cutters in there. I had them in my hand but no way to get close to it or even see it clearly without removing more engine parts. All I could do was feel it a bit with my fingertip. Maybe I missed an angle that would have room to work... I'll give it another try one day before giving up for good.

It is so often the case that taking off the panels is the easiest and fastest way to mess around with access to wiring on the RS. Once you get the hang of it and use something like a Milwaukee cordless driver, it is very straight forward. Also, with a driver, you can set the torque value and you don't leave screws undone, or too tight.

Having said that, a single T-25 screwdriver (not one with interchangeable tips) is also very useful as it is slim and can get into, for example, the "winglets" better than a electric driver.

Zitat von PeteT im Beitrag #5

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Zitat von Allan Redfox im Beitrag #4

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At the old forum I was the one who did lower the handlebars 17 mm by milling them. If any interested...

Good luck with the ty-wrap )))

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Hi Allan Redfox, any chance you could re-post your pictures and story of the milling? It would be good to capture your efforts into this new forum for posterity. Maybe start a new thread for Lowering Handlebars.

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Zitat von shootersteve im Beitrag #1

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I then discovered a zip tie buried deep inside in between the frame and engine, radiator etc. I could barely feel it with a fingertip to confirm this was the culprit. After an hour of trying to reach or even see it clearly, I had to give up. I couldn't just get anything close to it to cut it without fear of cutting another wire in the bundle. I'm assuming this extra zip tie was something not encountered in others doing this mod. Has anyone else run into this? Is there a solution I'm not seeing?

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