Helibar install on the clutch side

[whistler]

I plan on installing Helibars on my scoot, and I know Helibar's website claims their bars "retain all stock cables and hoses." However, my clutch line just doesn't seem to have quite enough slack to accommodate the Helibar's rise and setback.

Should I expect to re-route the clutch line, or does someone know of an OEM or aftermarket line that's about 1 1/2" longer than the stock line on an 'O6 Viffer?

Thanks for any info you can spare.

[kia001]

It fits, don't sweat it.

[whistler]

Thanks for the info.

[Gatekeeper]

Do you still have to grind off the tabs on 6th gen like you do on the 4th gen? Easy to do, but wondering. I also had to pull the top triple to reroute the throttle cables, but it was all in the instructions. So, it wasn't a surprise.

[olivino]

I installed them recently on my 07, the only tab you need to cut is on the right side (throttle side). Everything else fit no problem.

[chris2711]

Who'd a thunk it?

I also have a set I'm about to install on my 06 and contacted Helibar with a question not covered in the instructions, bar ends. The site says they retain the stock cables, hydraulic lines, and bar ends. But the helibars are not threaded at the end.

Jaime at Helibar quickly answered my email with a detailed photo and instruction for removing the stock damper unit and use it in the helibars.
Who'd a thunk it? All my other bikes had welded bar ends.

Attached is the document Jaime sent.



Removing Damper Units from Stock Handlebar(s)
We recommend that you use some rubbing alcohol to help release the rubber bushings from the inside of the tube. Run some alcohol into the control locking pinhole and into the bar end, and distribute in all directions.

Carefully place the bar in a vise with soft jaws and a rag. Reinstall the damper weight and tighten, making sure the ridge on the weight is properly engaged with the corresponding ridge on the damper unit. Hold onto the weight with one hand. While pulling out and twisting, depress the two retaining tabs on either side one at a time until they move past their locating holes. Continue pulling and twisting until the damper comes out (Note: there is an "o" ring on the inner end of the damper shaft that can be rubbed off inside the tube when pulling). Just shake it out. Repeat this procedure for the other side.

Clean the damper rubbers and shafts, and reinstall into the Heli Bars. Use a bit of rubbing alcohol as a lubricant to ease installation. With the damper weight still attached, carefully start the first rubber bushing into the bar. Push and twist until the set of two bushings is ready to go in. Align the tabs on the retainer ring with the locating holes in the Heli Bar. Continue pushing in, making sure that the outer edge of the last bushing enters the tube evenly. Press in until the tabs enter the two holes. If necessary, pull back out a bit until the tabs are against the rear edges of the holes.

CAUTION: If the right-hand unit is installed too deeply, the damper weight will interfere with throttle operation. The threaded end of the damper unit will be about flush with the tube end, but the ridge that engages the weight will protrude.
Once each unit is installed, remove the damper weight.

[MonkeyNuke]

Chris,
How did the installation go? Did you have any difficulty in removing the damper thing on the inside of the bar? Was it difficult to insert it in the new Heli bar?

Thanks in advance.

[chris2711]

Removing the dampner was a BITCH! In hind site I should have just purchased new ones, their rather cheap, and left the stock bars alone.

Tips: If you do not have a mounted vise as I do not, remove the bar, put a few drops of oil in the holes, let it coat the inside, than re-instal the bar and remove the dampner. Much easier to pull on this way.
The key is to push the two triangle tabs in the holes closest to the bar end to the side so they don't stop the dampner from being pulled out.
Once you get the tabs moved aside it's just a matter of pulling and turning the bar end. There are two rubber washers on the dampner that do not want to move.
Just clean up the dampner, apply a little lube and slide them into the new bars.

I did the instal, and have since removed the Heli bars and replaced the stock ones. The new position just didn't suit me. I never had a problem with the stock position, just wanted to see if the Heli bars would make that much of a difference. Probably going to post them for sale.

Later.