Need some advice for my 2003 620. HELP!!!

[Spidey]

I looked around in the FAQ section, but didn't find it.  Has this been turned into an FAQ yet?

Not yet.  I've got about 4 FAQ articles that are half-done.  I'm have to add a section about triples clamps to it and then I'll get it done.  Thanks for the bump to get me motivated.     Is there something you want me to add?

[teddy037.2]

heyyyy.. that lil'red pos looks awful familiar

 

[DarkStaR]

Not yet.  I've got about 4 FAQ articles that are half-done.  I'm have to add a section about triples clamps to it and then I'll get it done.  Thanks for the bump to get me motivated.     Is there something you want me to add?

Thanks, but I have nothing to add.  Just looking for pics of installed clip-ons to compare.

This may sound silly, but I'm thinking about replacing my Tomaselli clip-ons with something less adjustable.  Trying to get each side right is a PITA!!!  I want to powder coat some parts up front, and I don't want to have to deal with setting up the clip-ons again.

[Spidey]

Trying to get each side right is a PITA!!!

Safety wire, a straightedge and a protractor, my friend.  Use the line between the top of the fork legs as a baseline.  Or ya could just eyeball it.

[Privateer]

I want to fix up the rear a bit. I don't want to do a tail chop but I would be happy to just take the bottom part of the fender out and get one of those license plate mounting brackets.  I think I can have this made, however, I need exact measurements. If anyone is kind enough to give me the dimensions or take very detailed pictures of their I would greatly appreciate it. 

if you just want to take off the 'lower' part that holds the license plate, it just unbolts.  There are four nuts to loosen, the plate holder part comes off, then you can leave just the fender/water deflector and rig up a plate holder and some bolts.  I did my own in maybe an hour in the garage with basic hand tools (an hour because I didn't like the first one so I made another).



Andy

[gh0stie]

So I need help installing my Woodcraft 50mm Clip-ons on my '02 620

First question I can't figure out is whether to install above or below the tripple

Here is a picture of what it looks like right now





something tells me it ain't quite right and it needs to go below....(ok, you can stop laughing now)

Which leads me to my next question; how do I get the tripple off? I cannot seem to remove this "cap"




Also, in the second picture, can you tell me if the clip on is on the right way? or should I flip it like thus

[Howie]

Not much contact there, I would go below the triple, or lower the front, which will affect handling. 

[Raux]

to start

remove your light, dash, etc. from teh top triple

the cap you pointed out is the fork cap and stays on

the bolts at the front of the top triple (only! not bottom) get loosened
the bolt in the center of the top triple holding that center cap tight gets loosened

then the triple comes up. it will not be easy. you need to separate the gaps at the three caps

once the triple is off
slide the bars on.. like in the second pic
then put the triple back on, torque it back to spec
adjust your bars- sit on the bike in a riding position and get comfortable.
make them even. tighten them down
put everything back together

[Raux]

not meaning this as an insult, cause i've done the same on my rebuild. get a mechanic you trust to oversee the install or check everything before you ride.

[suzyj]

You'll need to put the clipons under the triple, or else drop the triple down a bit, which will increase the head angle and affect the steering geometry.

The second photo shows them on the right way - in the first they will hit your tank when you try to turn.

There's a lot of work involved in fitting them - you have to first remove the top triple, by undoing the gauges, removing the sensor bracket (I find removing the headlight makes that easier), then undoing the three bolts that clamp the triple to the forks and steerer tube.  Then it can be pulled off, with some difficulty.

When you put the clipons on, you're likely to find problems with clearance between the stock indicators and the brake/clutch levers.  I ended up moving my indicators down a bit.  Also you'll find that routing the brake and clutch lines is a challenge, as there isn't much space and the lines are now too long.

You'll also either need to drill your clipon bars for the controls, or else file off the locating lugs on the controls.

[KrakHor9]

I also did the CRG's!  Love em!!

I ended up putting clip ons on but if you only want to replace the bar.. I would go with the suburban machinery bars.  Although it IS up to YOU...

Let the modding begin!!! 

[gh0stie]

thanks for the feedback all, I finally got around to it tonight and ran into another snag...how the hell do you get the bolt holding the center cap off? mine is wedged firmly behind the ignition/frame and I cannot seem to get to it with an Allen wrench

thanks!

[DarkStaR]

Turn the bars to the right.  You may have to lift the tank.

If you are using regular allan wrenches.... Good Luck.

I use an allen socket with an extension.

[gh0stie]

Turn the bars to the right.  You may have to lift the tank.

If you are using regular allan wrenches.... Good Luck.

I use an allen socket with an extension.

thanks, do you mean to the Left? I currently have it turned all the way to the left in this picture and it barely gives me a enough room even with the tank lifted. If I turn it all the way to the right then it would be completely obscured by the frame/tank

yes I was (foolishly) trying with allen wrenches, will pick up an allen socket tonight.

[KrakHor9]

When I did my clip ons on my 620, I thought I was in over my head... Just take your time and think it out.  And yes you should be able to get the that allen bolt with even a regular set of keys... seems odd if you are having a problem... When you are done, it will well be worth it the time...