HeliBars HR03161 Handlebar Relocation Adapter Instruction Manual

HeliBars HR03161 Handlebar Relocation Adapter

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 confi dent you will enjoy them.

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.

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 THE 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 HeliBars.
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:

1. Bars must not be used as a tie down point. (See attached ‘Trailering Instructions’).
2. Bars cannot be damaged, dented, or altered in any way.
3. Bars cannot be overtorqued.
4. Refund will be for product purchase price only, and credited to original purchaser only.
5. 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.
6. 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 Safe and Enjoy!

Installation Instructions

1” (25mm) Taller, 3/8” (10mm) Closer to Ride

WARNING: IMPROPER INSTALLATION COULD RESULT IN SERIOUS INJURY OR DEATH. HAVE A QUALIFIED MECHANIC INSTALL YOUR HELIBARS®.

TOOLS REQUIRED:

Blue painters tape, 8mm hex, 3/8” swivel handle/breaker bar, 3/8” rachet with long swivel arm, torque wrench with 17mm socket. It is highly recommended to use an assistant for installation.

1. Remove handlebar mounting screws.

   • Protect fuel tank and the top sides of the fairing with painters tape and clean shop rags. The 4 10mm x 1.25 pitch socket head cap screws are held in place with a thread lock compound. This demands the use of an 8mm hex in excellent condition and a swivel handle breaker bar. (See Photo #1 & #2) Notice the use of a piece of tubing to increase leverage. Make sure the 8mm hex socket remains fully engaged with the screw. This is the slow part as the rear two screws are time-consuming due to the location next to the steering head. Have your assistant hold the bar while the screws are removed.
   • To remove the forward 2 screws you will remove the clutch master cylinder and two spade electric connections on the left side and the brake master cylinder on the right side to gain access. Only remove one master cylinder at a time and wrap them in a rag. (See Photo #3, #4 & #5) on the left side. Use a 3/8 rachet with a long swivel arm. Cover the fork tube with several layers of painter’s tape to protect surface of fork tube from the tool. When screw is removed temporarily return clutch master cylinder to the bar tube and install clamp. It is NOT recommended to leave it unmounted until the last screw is removed. Remove the front brake master cylinder and sit it on a rag. Remove the fi nal screw. Carefully place the handlebar assembly on rags in front off the top triple clamp. It’s a good idea to have an assistant hold the bars. There are 2 plastic rings located on the bottom of the handlebars over the fork tube bores. ( See Photo #6, #7 & #8) These must be re-used in Step 2. and are easy to misplace.
     DO NOT LOSE OR MISPLACE THEM.

2. Install HeliBars Gen 3 handlebar riser

   • Locate both plastic rings (may be stuck to the bottom of bars) and place them over both fork tubes with the cylindrical lip facing up and the fl at ring (horizontal) on the bottom. ( See Photo #9 )

   • Place the HeliBar adapter so the logo can be read from the saddle. Make sure the two outer large bores engage the plastic rings. ( See Photo #10 )

   • Have your assistant position the bar assembly over the adapter. Use the blue Loctite included
     and coat the ends of the bolts 4-5 threads. ( See Photo #11 )

   • Insert bolts, align with threads and hand tighten all four bolts to assure no bolts are cross threaded (See Photo #12). Torque all 4 mounting bolts to 32 ft. lbs., use a 17mm socket. Adjust levers up or down and retighten master cylinders. Reconnect clutch micro-switch connectors.
     Remove all painters tape. ( See Photo #13 & #14)

!! CAUTION!!
HARDWARE MUST BE TORQUED TO SPECIFIED VALUES.
THEY MUST NOT BE OVER-TORQUED. OVERTIGHTENED
HARDWARE CAN LOSE INTEGRITY.
For questions regarding installation please call 1-800-859-4642. HELI MODIFIED, INC ASSUMES NO LIABILITY FOR ANY INJURY OR LOSS OF PROPERTY THAT MAY RESULT FROM IMPROPER INSTALLATION OR USE OF ANY HELIBARS PRODUCT.

IMPORTANT INFORMATION

ABOUT POWDER-COATED HELIBARS

HeliBars® are finished with a polyester powder coating. Polyester is recommended for outdoor use because of it’s excellent UV resistant quality; if we were to use 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 fi nish 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 fi nal adjustments are made; in this way you will lessen the possibility of scratching.

NOTE: Powder coat fi nish is not indestructible, there are chemicals that may react negatively when applied to fi nish. Brake fl uid 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 HeliBars, 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.

HR03161 Suzuki Hayabusa Handlebar Relocation Adapters Installation Instructions
~ 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

References

• HeliBars

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