Date: Tuesday, April 10, 2001
By: James Wilkins
I recently prepared my SV650 for the track to include the use of Vortex clip-ons. I also wanted to bring it back to the street for the occasional cruise. The problem was remounting the headlight brackets, turn signals, etc. while still using the clip-ons. I searched the web for ideas and found lots of useful tips. However, none of the tips suggested were neat and clean. Most things suggested included some kind of cutting, welding, fabrication, or modification. I experimented myself, and in no time at all (less than an hour) I discovered that it can be done quickly and cleanly with no alteration or fabrication of parts. Here's how it goes (I will start assuming that the light brackets and all the other junk is already off - you will need shorter brake lines - go get some steel braided lines):
- Lift front of bike (use a proper stand).
- Remove steering stem nut (make sure that you use the steering stops to counter the force of your wrench).
- Loosen top-fork-clamp pinch bolts.
- Gently remove top-fork-clamp (be careful - don't crush the threads on the steering stem).
- Slip on the headlight brackets upside down (stock right bracket goes to left fork and vice versa).
- Use soap on the rubber guides (makes it nice and easy).
- Slide your clip-on mounting hardware on the fork tube between top and bottom of headlight bracket.
- Re-install top-fork-clamp (tighten steering stem nut using steering stops and then pinch bolts).
- Slide clip-on mounting hardware up against underside of headlight bracket, position, and tighten.
- From top to bottom it looks like this: top-fork-clamp, top of headlight mounting bracket, clip-on hardware, and bottom of headlight mounting bracket.
- There is a black mounting bracket at the bottom of the headlight assembly (attaches headlight to frame). Remove this bracket and gently bend the tabs - both ends (decrease the angle between the tabs and the longer part of the bracket). This brings the headlight just slightly closer to the frame and aligns the headlight with the triangular aluminum headlight brackets.
- Remount brackets, headlight, turn signals, etc.
- §The turn signals (reversed) will point slightly upwards but they are still visible from the front.
- Turn wheel from lock to lock and make sure you get clean steering. If not, try different positions with the wiring (easily done - inside or outside of brackets).
- You are done and everything is as good as new.
Tips:
- Do not over-tighten bolts, nuts, etc. Use torque specifications from manual.
- Ride the bike a few times and adjust the controls and mirrors accordingly for comfort. You will notice that the turn signals may be close to your clutch and brake levers. Don't worry about it - unless of course you have big hands or it causes an unsafe riding condition.
- Torque for pinch bolts is 16.5 ft-lbs. If your clip-ons do not come with torque specifications, hand-tighten. Do not exceed 16.5 ft-lbs. Steering stem nut is approximately 47.5 ft-lbs., I think. I don't have my manual in front of me so double check this and all torque settings before proceeding.
Use this information at your own risk and if you are not mechanically inclined, have a mechanic do it. Ride responsibly and check and re-check everything before you go for a ride. Clip-ons are not meant for street use. Check them frequently (make sure they are tight and that the bars are not bending or shearing).
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