1 Clutch side - cut off bar flush with end of switch cluster.

2 Throttle side - Remove Throttle rotor from switch cluster.

3 Replace switch cluster on bar. Cut handlebar 1/4" out from Switch Cluster. Be careful not to scratch or damage the switch cluster.

4 Hollow Both Bars - Bar end weights, weld ridges, and other obstructions must be cleared to allow for insertion of the FlatBars. Drill out them out or have them machined as per prep drawing.
On 7/8” Bars use a 11/16” bit. Go 3 “ deep.
On 1” bars use a 13/16” bit. Go 3 “ deep.

5. Clean the metal after the cuts, smoothing both inside and outside edges with metal files and sanding equipment.

6. Prepare the clutch assembly - Remove the bolt from the FlatBar clutch assembly and put blue locktite on the threads as shown above. Re-insert the bolt and lightly screw it into the nut. Don't expand the grommet yet.

7. Moisten the inside of the bar and put a film of Gorilla Glue on the outside surface of the whtie grommets. 

8. Insert the FlatBar into the handlebar.Turn thumb relief toward you, then put the hex key into the bolt head. Tapping the hex key stretches the grommet, easing insertion. If necessary, Shim with blue damper tape. You want a a snug fit with no wrinkles.

9. Turn the hex key clockwise to tighten the assembly within the FlatBar. You’ll feel when the resistance gets really stiff. Allow adhesives to set. Do not rotate the FlatBar more than 180 degrees at any time.

INSTALLING THE THROTTLE SIDE

10. Slide conversion tool onto the plastic rotor against the throttle switch. Tighten set screws gently to hold tool in place. Cut the plastic throttle tube at the outside edge of the tool. Clean up the edges by sanding or filing. Discard the end.

11. Using the conversion tool as a guide: EITHER
(A) Drill 4 screw holes where indicated; OR
(B) Dremel at low speed, or drill out at high speed with roto-zip bit, the 4 slots.
NOTE: Slots allow for widest angle adjustment. Start each hole with a small pilot hole, and be careful NOT to crack the plastic rotor while drilling. If the rotor cracks it in two places, replace it.

12. Loosen screws and remove the conversion tool. Re-install the altered throttle rotor into the switch housing, loosely clamp the housing onto the bar. Return the throttle switch cluster to its original position.

13. Slide the pre-sized FlatBar throttle into the cut off handlebar and pre-drilled rotor, until you see the screwholes through the slots. Tighten the throttle switch cluster mounting screws.

14. Screw in the 4 throttle screws and washers through the throttle rotor into the FlatBar. Use every other hole, with one screw in each slot. The screws should be tight enough to keep the throttle from turning within the rotor or vibrating loose. FlatBar Tuning: start out with the far edge of the FlatBar slightly above the near edge. This will put the throttle at a pleasing angle on the road. Adjust as necessary WHEN STOPPED.

15. Take a short a short ride to check your throttle angle. Get to your normal highway speed. Your wrist should be neutral at your normal speed. Stop and readjust if neccessary. Put Locktite on the screws. Tighten them down. Don't strip the Phillisp screws. Pull the grip up over the screw heads. Take most of the slack out of the throttle cables. You're done. Enjoy.

Contact Ken Hunter for Installation questions, or call 415-786-6312.

PRODUCTS