Bike: ’06 S2R 800 Dark
Tools: hacksaw, dremel, bondo, high temp engine enamel primer and low gloss black paint
Parts: new
Rizoma Zero 11 turn signals
I’m still working my way through a “how much more black could it be?” quest, so I decided to combine a few mods and paint a few more parts black at the same time.
I never quite cared for the shape of the stock turn signal/headlight bracket with the unused extra holes (after removing stock lights) and ridge along the top. I also never plan on getting a wind screen and don’t like the unused mounting tabs sticking out, so I decided to make a few cuts and move the turn signal holes.
In the first pic below you can see the bracket where the turn signals mount. I used the hacksaw to make a nice clean line. Then I used bondo to fill the old holes, made new holes a bit lower. On the U bracket I cut along that red line with a dremel and carefully removed the wind screen mounts. I like the stock handlebar and gauge cluster height, and don't have welding equipment yet, so I didn't tackle lowering the U bracket parts like others have. I think if I ever went with clip-ons I'd go that route next.
Once I removed the instrument gauge cluster and headlight, it was easier to see the mess of wires and where the U bracket was attached and how to get it off.
Had to clip a few zip ties and remove the nuts on the middle part of the U bracket (I’ll call that the mini U bracket). The two threaded parts w/rubber where the instrument gauges mounted screw in above the main U bracket. Those come out easy.
Crummy picture cut off at the bottom, sorry, but you can just see where the two bolts in the middle obviously need to come out to help remove the main U bracket. This freed up the brake lines to pop out, but the U bracket was still well attached and not having done this before it was difficult to know how much force it should take to get it free.
Being careful I wiggled it and gave a few gentle taps with a rubber mallet and off it popped to reveal a plastic bit it slides onto on each side at the top.
Here are the bulk of the parts removed, ready for cutting, sanding, priming, more sanding and painting.
Here’s the end result. More black, and new Rizoma Zero 11 signals. Those things are bright, and you can see them from front, back, and side. Also painted the ring around the headlight. I think now I really need new black triples or black forks.
I should have taken a pic of the inside of the headlight ring. Man that was a surprise. I didn’t expect to see all these thin bent metal “needles” around the edge. They overlap each other and lock into place to provide tension to keep the ring in place, that plus one screw. Odd. Here’s a pic I snagged from the manual.
