TS05158 BMW S1000RR 2019+ TracStar Replacement Handlebars Instruction Manual
- June 4, 2024
- BARS
Table of Contents
TS05158 BMW S1000RR 2019+ TracStar Replacement Handlebars Instruction
Manual
IMPORTANT:
PLEASE GIVE CUSTOMER ENCLOSED INFORMATION!
Thank you for your purchase of our HeliBars®. They are designed to increase
your long distance
comfort and improve the handling of your sport motorcycle, and we feel
confident you will enjoy them.
Your HeliBars are designed to fi t your motorcycle with little to no
modifications needed to your stock cables and hydraulic lines. In order to
achieve this fit, we do not simply increase the height at the fork tube/triple
clamp area. If we were to mirror the angle of your stock handlebars, the
HeliBars would not fit and clear your stock equipment, and lock to lock
steering
clearance would be impossible.
If you hold up the HeliBars and compare it to your stock handlebar, the difference may not be readily evident. One test we can suggest is to take your stock handlebar, and the corresponding HeliBars, and set them both on a flat surface. You can see the angle difference. Then install the left HeliBars, following the instructions. Walk around the front of your bike and look through the windshield. You should see a noticeable difference between your stock handlebar and the HeliBars. Finish the installation, and try them out. We think you’ll like them!
HeliBars INSTALLATION
IMPROPER INSTALLATION COULD RESULT IN SERIOUS INJURY OR DEATH. HAVE A
QUALIFIED MECHANIC INSTALL YOUR HeliBars.
IF WE HAVE NOT INCLUDED SPECIFIC INSTRUCTIONS FOR YOUR MOTORCYCLE, THEN THE INSTALLATION IS SIMPLY A REVERSAL OF THE DISASSEMBLY PROCESS. **NOTE THE LOCATION OF LINES AND CABLES. BE SURE TO CLEAN THE FORK TUBES BEFORE INSTALLATION!!
!! CAUTION !! MAKE SURE THE HeliBars ARE FULLY SEATED. TIGHTEN BAR END DAMPER
WEIGHTS FIRMLY. AFTER INSTALLATION, MOVE BARS LOCK TO LOCK AND CHECK CLEARANCE
OF: 1.CABLES 2. HYDRAULIC LINES
3.WIRES 4.FAIRING 5.FUEL TANK. TORQUE ALL HARDWARE TO MANUFACTURER’S
SPECIFICATIONS.
IF YOU HAVE INSTALLATION QUESTIONS, PLEASE CALL 1-800-859-4642.
HELI MODIFIED, INC. ASSUMES NO LIABILITY FOR ANY INJURY OR LOSS OF
PROPERTY WHICH MAY RESULT FROM IMPROPER INSTALLATION OR USE OF
ANY HeliBars.
WARRANTY / RETURN POLICY
We make every eff ort to build a quality product so you can fully enjoy your riding experience. Thank you for your order.
HeliBars® may be returned for defects in materials and workmanship within one year from the date of shipment to the original purchaser, in which event the purchaser may receive a replacement set of Heli- Bars.
If within thirty (30) days of the shipping date you are not satisfi ed for any reason, you can return the HeliBars. Return policy is valid for original purchaser only. If HeliBars are purchased from a vendor other than Heli Modifi ed, Inc., customer must contact vendor where purchased regarding returns. Refund will be extended to original purchaser only. There are no other warranties which extend beyond this. Conditions of this 30 day return policy:
-
Bars must not be used as a tie down point. (See attached ‘Trailering Instructions’).
-
Bars cannot be damaged, dented, or altered in any way.
-
Bars cannot be overtorqued.
-
Refund will be for product purchase price only, and credited to original purchaser
only. -
Product must be returned with all original equipment, documents and in original packaging. There must be no physical damage caused by the customer or by carrier.
-
A Return Authorization Number must be obtained from us before you return the product.
We reserve the right to charge a re-stocking fee of up to 25% if the above
criteria are not met.
THERE ARE NO FURTHER EXPRESS OR IMPLIED WARRANTIES INCLUDING,
BUT NOT LIMITED TO, IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. By accepting this product, the consumer agrees to
arbitrate and litigate any controversy in the State of Maine, and under the
laws of the State of Maine.
HELI MODIFIED INC. ASSUMES NO LIABILITY FOR ANY INJURY OR LOSS OF
PROPERTY WHICH RESULT FROM IMPROPER INSTALLATION OR USE OF ANY
HELI BARS. ALL HELI MODIFIED, INC. PRODUCTS SHOULD BE INSTALLED BY
A QUALIFIED MECHANIC. IMPROPER INSTALLATION MAY CAUSE DEATH OR
INJURY.
Ride SaMade in the USA is etched on the left TracStar Clip-on.fe and Enjoy!
31.75mm Taller (1 1/4”) ~ 12.7mm Rearward (1/2”) ~ Stock Width
WARNING: IMPROPER INSTALLATION COULD RESULT IN SERIOUS INJURY OR
DEATH. HAVE A QUALIFIED MECHANIC INSTALL YOUR HELIBARS®
Made in the USA is etched on the left TracStar Clip-on.
1.) 1. Remove left handlebar and controls.
a. Place protective cover on the fuel tank and the sides of the fairing.
b. Loosen and remove the left damper weight and hardware. Use a T40 torx. (See
Photo #1)
c. Fold back the rear side of the left grip to access mounting screw and
remove. Use a T15
Torx. (See Photo #2)
d. Using a T30 Torx bit loosen and remove the two clutch strap pinch bolts and
rest the clutch lever on the covered fairing. (See Photo #3)
e. Loosen and remove the left handlebar pinch bolt using a T45 Torx bit. (See
Photo #4)
f. Loosen and remove pivot screw using a T30 torx. (See Photo #5) Gently twist
grip backward and forward while withdrawing left clip-on from grip/housing.
2.) Install left TracStar (Made in the USA laser etched).
a. Slide left grip/housing onto the left TracStar bar tube and line up the
mounting screw holes, install screw and tighten using a T15 Torx screw drive.
(See Photo #6) for correct bar orientation.
b. Install left TracStar into top triple clamp and install pivot hardware. We
recommend using blue loctite. Tighten with a T30 Torx to 8 newton meters/6 ft
lbs. (See Photo #7)
c. Rotate the TracStar so it’s fi rmly up against the fork tube. Carefully
install the 8mm pinch bolt by hand making sure it is not cross threaded. Using
a T45 Torx bit torque the screw to 19 newton meters/14ft lbs. (See Photo #8)
d. Install clutch lever strap clamp and screws. Make sure clamp arrow is
facing UP. Keep clamp close to left control housing and tighten top pinch bolt
fi rst. Adjust clutch lever up or down and fi rmly tighten lower pinch bolt.
(See Photo #9)
e. Re-install left damper weight and torque to 12 ft. lbs. (See Photo #10) for
completed left side.
3.) Remove right handlebar and controls.
a. Remove right damper weight.
b. Remove resevoir mounting bracket screw. (See Photo #11) Cover bracket with
a piece of painters tape or wrap in a rag to keep it from scarring and
scratching the fork tube.
c. Remove front brake master cylinder screws and clamp. Set master cylinder on
a rag. Remove
any rubber cable ties holding wires to brake hydraulic line.
d. Remove right handlebar pinch bolt using a T45 Torx bit. (See Photo #12)
e. Remove right pinch bolt using a T30 (See Photo #13).
f. Using a long reach T8 Torx bit, remove screw from the bottom of the
throttle housing control. (See Photo #14)
g. Snap apart the forward half of the cover from the housing and carefully
remove it. (See Photo #15)
h. Loosen and remove the screw holding the top of the right control housing.
(See Photo #16)
i. Hold the top cover to the side and loosen and remove the screw holding the
throttle assembly
to the right handlebar. (See Photo #17)
j. Withdraw stock right handlebar from throttle housing.
4.) Install right TracStar and controls.
a. Slide throttle housing onto right TracStar, align holes, install screw and
tighten. (See Photo #17) Bar should be orientated so you can read logo
etchings.
b. Re-install top cover and mounting screw (Photo #18)
c. Carefully, re-install the lower throttle housing cover. Snap the forward
half together, reinstall
the screw and tighten. Remember you are tightening into plastic so don’t over
do it! (See Photo #19)
d. Engage rear pivot of the Tracstar into the top triple clamp and install the
pivot screw. Blue loctite is recommended. Torque to 8 newton meters/6 ft lbs.
with T30 Torx. (Photo #20)
e. Rotate right TracStar forward until it contacts fork tube, install pinch
bolt and torque to
19 newton meters/14ft lbs. (See Photo #21)
f. Re-mount front brake master cylinder, as per the left side but snug up the
top pinch bolt only at this time.
g. Align resevoir bracket with mounting slot, hand start screws and torque.
(See Photo #22)
h. Adjust front brake lever up or down, tighten top, then botton screws.
i. Install right damper weight to 12 ft lbs.
Double check all work performed.
!! CAUTION!! BARS MUST BE TORQUED TO SPECIFIED VALUES.
THEY MUST NOT BE OVERTORQUED. OVERTIGHTENED HARDWARE CAN LOSE INTEGRITY.
HELI MODIFIED, INC. ASSUMES NO LIABILITY FOR ANY INJURY OR LOSS OF PROPERTY WHICH MAY RESULT FROM
IMPROPER INSTALLATION OR USE OF ANY HELIBARS.
All text & photos © Heli Modified Inc. 2012
IMPORTANT INFORMATION
ABOUT POWDER COATED HELIBARS
HeliBars® are finished with a polyester powder coating. The polyester is recommended for outdoor use because of it’s excellent UV resistant quality; if we were to use an epoxy it would tend to fade and chalk pretty quickly when exposed to sunlight and UV rays.
Care must be taken during installation because the finish can be scratched by the sharp surfaces of the controls and master cylinder clamps. When mounting the master cylinders to bars, do not let them move around the bars with the caps loose. Mount them in the proper position and hand tighten the screws until final adjustments are made; in this way you will lessen the possibility of scratching.
NOTE: Powder coat finish is not indestructible, there are chemicals which may react negatively when applied to finish. Brake fluid may cause deterioration of the finish. We do not recommend the use of acetone or similar chemicals for cleaning purposes. We would recommend the use of an over-the-counter adhesive remover (such as Goo Gone) for the removal of any extraneous material. Please read labels directions for any cleaning/polishing product before use. If you have any questions regarding the use of any over-counter-products with the Heli-Bars, please call us before applying them to the powder coated finish.
If care is taken during installation, your HeliBars will continue to look as good as when they were new. They will look great for years to come with a bit of wax and careful cleaning.
Thank you for your purchase, ride safe and enjoy!
Sincerely,
Harry Eddy, President
Trailering with HeliBars®
HeliBars clip ons and handlebars must not be used as the primary holding points for tie downs while trailering. As with your stock bars applying extreme force to the ends of the bars can bend the bars or rotate them on their mounts.
Use a wheel chock and pull the machine down and forward using soft ties or similar, attached to the lower triple clamp.
Bars should only be used as secondary attachment points to steady the motorcycle from lateral sway.
Failure to follow these guidelines can cause damage to the bars and the motorcycle, and may also void our warranty.
Installation Instructions – BMW S1000RR – TS05158 – 2020+
~ PO Box 638 ~ 20 Industrial Way ~ Cornish, ME 04020
Toll Free: 800-859-4642 ~ Int’l:
207-625-4642 ~ Fax:
207-625-3024 ~
www.HeliBars.com
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References
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