Clip-on Conversion Write-up w/636 Forks

Here is how I converted to Clip-Ons below the upper triple. There are many ways to do it. This conversion is great for the track. I took a few short test rides, the longest was maybe 45 minutes. My lower back was hurting; although, I think I have become slightly used to the position now.

The performance benefits are great. The angle of the wrist when hanging to one side allows for better throttle control. When I first got to the track after doing this mod I might have only ridden the bike 3 times with this setup. After two or three turns (not even a lap) I knew it was going to be great. I barely touched a peg all day, where as the previous trackday I was struggling to keep them off the ground. It took some focus to keep the weight off the wrist, especially trying to get back in the saddle coming out of turns, but a few sessions later I had the idea. As I got tired through the day I had to remind myself as I began to pull on the bars some exiting corners. To me this is just bad form and a lack of leg/core strength which I am working on.


Trials & Errors (my thread during the project: many questions answered here):
http://www.riderforums.com/showthread.php?t=59493

Anyways, here is how I did it.....


Specs:
Z1000, ZX636 Forks, 2001 ZX9 Master Cylinder, Woodcraft 48mm (CBR600) Clip-ons, Spiegler Custom Brake Lines, Pilot Headlights

Description:
My goal was to use clip-ons below the upper triple without cutting the front fairing. Due to the way everything routed I had to replace the brake lines and headlight, and move the front fairing forward 2 3/4". I needed to keep some kind of headlight for doing test rides on the street, and so I can occasionally haul the bike to the mountains, but my main goal was to make the bike perform better at the track.




All Parts Needed:
Clip-Ons
Brake Lines
Headlights
Custom Brackets
Grips

Clip-Ons
Woodcraft 48mm (CBR600 05+) Clip-ons plus 1 replacement bar (optional) - $155 shipped (STG)

Compared to 636 Clipons (which I first attempted to use)


Turn Signal brackets had to go


Difference between handlebars and clip-ons


Brake Lines
Spiegler Two Line Kit (Black Steel Braided Lines w/Charcoal Fittings) - $130 shipped (direct from Spiegler)
Line 1: 648mm Fitting 1: 090 Fitting 2: 000
Line 2: 685mm Fitting 1: 090 Fitting 2: 000

*** Note: For the Bottom Fittings (#2) I should have gone with Fitting 002 for the caliper side

Brake lines were too long: replaced with shorter lines & different master fittings


Relocated the brake line "hoop" to the front-lower stock headlight bracket


Relocated the brake reservoir and added two brackets to support it




Added this bleeder banjo bolt




Headlights
Pilot 55W OEM Driving Lights - $20

Fabbed up the new headlight bracket which bolts between the fairing and the existing headlight bracket


Lower bracket bolts to fairing where lower headlight bolt used to mount


Upper mount


First time bike was ride-able in over a month


Quick test ride, at night of all times


The headlights bounced alot, so I added two more supports to bridge upper/lower brackets


Bracket without lights


Bracket off the bike





Pieces


Pieces


Sections



Custom Brackets (See Picture Below for individual pieces) - $12 (and many hours)

All Fairing/Headlight brackets made from 1" wide X 1/8" thick flat aluminum sticks (Home Depot). Bracket pieces were cut to the dimensions below and then trimmed back to line up. All dimensions and angles below are rough estimates.

A. Fairing Upper Extender x 2
Start with 6" piece; make 150* Bend with 1 1/4" extension; make 30* bend with 1 3/8" extension, leaving center straight at 2 3/4".

B. Upper Bracket Stabilizer x 1
5 3/8" piece.

C. Fairing Lower Extender x 2
C-1. Start with 4" piece; make 90* Bend with 1" extension, leaving 3" straight; trimmed to 7/8" vertical with 2 3/4" straight.
C-2. 2" piece.

D. Headlight lowering bracket x 2
Start with 4" piece; make 90* Bend with 1 5/8" extension, leaving 2 3/8" straight; trimmed to 2 1/4" vertical with 1 3/8" straight.

E. Headlight Mount x 1
9" piece.

F. Headlight Mount Stabilizer x 2
Start with 5 1/2" piece; make 55* Bend with 1 1/2" Extension; make 55* Bend with 2 3/4" Extension, leaving 1 1/4" center straight. Cut ~ 30* angle on bottom (1 1/2" extension) so stabilizer reaches Headlight Mount. Cut ~30* angle on outside of bottom to clear the inside of the fairing. (Many combinations of angles and lengths will work here; using trial and error I reached this one on the third try; although, I could have just drawn it on paper and used simple geometry)




Trimmed, Smoothed and Painted






Track Mode


With lights


Street Mode


Before & After Comparisons








Summary:
The bars clear the tank on full lock; although, a violent tank-slapper may break my wrist. The 2 3/4" gap between the upper fairing is noticeable, but doesn't bother me much. Besides having to switch the brake lines out it wouldn't be too hard to go back to handlebars. I haven't even thought about mirrors or front blinkers until just now.

All-in-All it was a fun project, and very worth the effort for track performance.

Cheers! :alcy: