February 23, 2012

Z1K Sport Bar Installation Guide


  1. Remove the factory handle bar clamp, and move the bars toward tank out of the way.
  2. Then remove the plastic dash cover that surrounds the instrument panel, it is held on using 2 bolts on the sides, and 2 push-in's on each side of the instrument cluster

 
(a photo of the mounting points on the plastic cover)


(And the mounting points on the bike itself)


(The brake hose and throttle cables will be bunched up when you lower them down for the sportbars. At the point circled you may have to trim the plastic to provide clearance.)

  1. Install the sportbar base assembly with the supplied socket head bolts.

 

  1. Take both the brake reservoir (right side) and clutch lever (left side) completely off the handle bar. Two bolts apiece.
  1. Remove your right and left hand switch housings from the handlebar without completely separating the back cover from the front switch panel (this will make installation easier and keep the opening and closing throttle cables from popping out of the right hand housing)

 

  1. Take your Right hand bar (the location pin hole will be drilled farthest from your bar end) and slide the Switch housing onto the bar. Be sure the location pin is in the hole before tightening the housing, or you will snap the pin off of the plastic housing.
  1. Slide the bar into the base assembly, twisting the switch panel to your liking.

 

  1. Take the Left hand bar (the location pin hole will be drilled closest to the bar end) and slide the switch housing into the bar. Again, be sure you have the location pin in its hole before securing the housing to the bar.
  1. Slide the left bar into the base assembly, again twisiting the switch housing to your liking.

 

  1. Attach the brake master cylinder to the Right hand bar, and the Clutch lever to the Left hand bar. Be sure you slide the cables and hoses to where you will not be pinching them, or restricting movement.

During this process you will need to constantly moving and adjusting all of the hoses and cables, as this product lowers everything quite a bit. Throttle action should be crisp and always snap back from full throttle. Clutch should work smoothly.

Give the bars a once over to ensure you have tightened everything completely, then you're done!