Helibars fitted to ZX12R A1 - Kawasaki Forum :: KawasakiWorld.com
 
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post #1 of 7 Old 03-14-2005, 01:36 PM Thread Starter
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Helibars fitted to ZX12R A1

Finally managed to get the helibars fitted to my ZX12, In case anyone is thinking of doing the same, here is my experience!

The original bars have something of a reputation for being a pig to undo - taking the advice from this forum I got hold of a brand new hex socket for the job. The first bolt wouldn't budge with a standard rachet and it looked like it was starting to round off I fitted the hex socket to a 24" breaker bar and covered the socket in ScrewGrab to increase the grip on the bolt head. No problem it came out easily - the bolt was covered in red threadlock for it entire length. Same treatment for the righthand bolt, this time the breaker bar was bending and I thought it would round off, but the screwgrab seemed to hold and the bolt turned.

Tip 1 - with all the threadlock on the bolt you have keep the socket pressed quite firmly into the bolt head - as the bolt is undone it pushes the handlebar out from the top yoke. Make sure you push it back into the yoke otherwise it will move out far enough for the locating pin to disengage from its slot, the handle bar turns and the pin scratches the black paint

Fitting the new Helibars was not a problem - I bought new bolts for the bars which came with threadlock already on the threads. The lefthand switchgear and new clutch cable went in a treat.

The righthand bar was a different matter. The hole for the locating lug for the switchgear was in the wrong place:-



After some e-mail correspondence with Helibar (Excellent customer service btw) they were confused. The reason suprised me - The source of the confusion lies with Kawasaki (and to some extent Governments!). Motorcycle legislation in many countries is moving towards the compulsory use of the headlight, even during the day. (Not sure if this is the case in the US, but it is in the UK and Europe). To ensure compliance, Kawasaki like most other manufacturers has removed the off-sidelight-headlight switch from their bikes so the owner cannot switch off the headlight. This was not the case in 2000 when my bike was manufactured. My righthand switchgear is split horizontally, later models of ZX12R are split vertically. The locating lug is in a different place. Helibar are now aware of this - if you have a horizontally split righthand switchgear contact Helibar before ordering.

Easy to fix - I just drilled a new hole (4.5mm) for my switchgear.

Tip 2 - I bought a new left grip (about £10) - I might refit the old bars one day! Getting the new grip on was right bitch. No glue needed on that b*st*rd!! I pinched a couple of thin plastic "sticks" from my sons technix set shaved a rough point on the end and pushed them up between grip and the bar - this gave something grip on to.

I fitted Goodridge braided hoses to my 12R - unfortunately these are shorter that the stock lines by about 12mm so I had to get Goodridge to make up some custom lines - no extra charge for that - The Goodridge lines for the front are a complete set with a special union, which cannot be dismantled, so all three lines need to be bought - again! So I have a set of standard braided lines for sale on Ebay (plug!)

The throttle cables now emerge behind the brake reservoir - if you have a spongy front brake you will need to get it sorted out, because the brake lever could come back and hit the cable housing.

On full left lock the rubber sleeve on the throttle cables just touches the fairing - shouldn't be a problem.

Because the front brake reservoir is raised above the top yoke bar mounting points I haven't been able to move the brake lever down around the handle bar as I did before, the reservoir hits the back of the top yoke bar mount - not a real problem as the whole setup feels great!

I haven't tried it on the road as there too much salt about - roll on spring!

2000 A1, PCIII, Yoshi RS3 full system, Muzzy advancer, A2 throttle boots
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post #2 of 7 Old 03-14-2005, 06:23 PM
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Chris, excellent, excellent job. I'm sure others will learn from your experience and pics. Good looking out.

BTW, glad i got the first gen bars due to the fitting issues. Mine went on rather quickly and fit my galfer lines perfect.
Jere has the 2nd Gen bars on his bike, they look sooooper comfy. Maybe on my next 12. :wink:
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post #3 of 7 Old 03-14-2005, 07:29 PM
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I've got Heli's on my A1 with Goodridge lines. Everything fit perfectly on mine.
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post #4 of 7 Old 03-15-2005, 12:01 AM Thread Starter
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Quote:
Originally Posted by ZXLNT
I've got Heli's on my A1 with Goodridge lines. Everything fit perfectly on mine.
Are they the first or second generation set?

No way would my Goodridge lines fit - as I say about 12mm too short. annoying or what!

2000 A1, PCIII, Yoshi RS3 full system, Muzzy advancer, A2 throttle boots
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post #5 of 7 Old 03-15-2005, 02:49 AM
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Been a couple years so 1st gen I would say.
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post #6 of 7 Old 03-15-2005, 03:03 PM
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barflys

My Helibars went on without a hitch-4 years ago on my 2000. 40,000 miles later, they still work perfectly. :D
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post #7 of 7 Old 03-16-2005, 12:02 AM Thread Starter
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I think the 2nd gen bars are raised slightly more than the 1st gen ones. Anyone know why they updated them?

2000 A1, PCIII, Yoshi RS3 full system, Muzzy advancer, A2 throttle boots
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