Klock Werks KWH-04-0507 1 1/4 Klip Hanger Handlebar

Introduction

This manual provides detailed instructions for the proper installation, operation, and maintenance of your Klock Werks KWH-04-0507 1 1/4 Klip Hanger Handlebar. Please read all instructions thoroughly before beginning installation to ensure safety and optimal performance. Professional installation is highly recommended.

Safety Information

WARNING: Improper installation or use of this product can lead to serious injury or death. Always wear appropriate safety gear when working on your motorcycle. If you are not confident in your mechanical abilities, seek assistance from a qualified motorcycle technician.

• Ensure the motorcycle is stable and secure before beginning any work.
• Disconnect the battery before working on electrical components.
• Verify all controls (throttle, clutch, brake) operate freely and correctly after installation.
• Check for proper cable and wire clearances throughout the full range of steering motion.
• Always use the correct torque specifications for all fasteners. Overtightening or undertightening can cause component failure.
• This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

Package Contents

Please verify that all components are present and undamaged before proceeding with installation.

Image: Contents of the Klock Werks KWH-04-0507 Klip Hanger Handlebar kit. Shown are the chrome handlebars, two chrome risers, various mounting bolts, a tube of adhesive (E6000), and a set of black control cables.

• Klock Werks 1 1/4 Klip Hanger Handlebar (Chrome)
• Mounting Hardware (bolts, washers)
• Control Cables (throttle, idle, clutch - specific to application)
• Adhesive (e.g., E6000)
• Installation Instructions (this manual)

Setup and Installation

Tools Required (not included): Basic hand tools, torque wrench, wire cutters/strippers, electrical tape, zip ties, service manual for your specific motorcycle model.

1. Prepare Motorcycle: Park the motorcycle on a level surface and secure it. Disconnect the negative terminal of the battery.
2. Remove Existing Handlebars:
   • Carefully remove all controls (throttle, clutch, brake master cylinder, switch housings) from the existing handlebars. Label wires and cables if necessary.
   • Disconnect all cables and electrical wiring from the controls.
   • Loosen and remove the handlebar clamp bolts, then remove the old handlebars.
3. Install New Handlebars:
   • Position the Klock Werks Klip Hanger Handlebar into the handlebar clamps. Do not fully tighten yet.
   • Adjust the handlebar to your desired position, ensuring comfortable reach and control.
   • Tighten the handlebar clamp bolts according to your motorcycle's service manual torque specifications. Ensure even tightening.
4. Route Cables and Wires:
   • Route the new control cables and electrical wiring through the internal channels of the Klip Hanger Handlebar, if applicable, or externally as per your motorcycle's design.
   • Ensure cables and wires are routed smoothly, without kinks, pinches, or excessive tension. Verify they have sufficient slack for full steering lock in both directions.
   • Connect the new cables to the appropriate controls and the motorcycle's system.
5. Install Controls:
   • Reinstall all controls (throttle, clutch, brake master cylinder, switch housings) onto the new handlebars.
   • Use the provided adhesive (e.g., E6000) for grip installation, if applicable, following the adhesive manufacturer's instructions.
   • Ensure all controls are securely fastened and operate smoothly without binding.
6. Final Checks:
   • Reconnect the battery.
   • Test all controls: throttle (smooth return), clutch (full engagement/disengagement), front brake, turn signals, horn, and any other handlebar-mounted switches.
   • Turn the handlebars from full left lock to full right lock, ensuring no cables or wires are stretched, pinched, or interfere with any other components.
   • Verify all fasteners are tightened to the correct torque specifications.

Operating Considerations

After installing your new handlebars, it is important to familiarize yourself with the new ergonomics and handling characteristics of your motorcycle.

• Initial Ride: Perform a short, low-speed test ride in a safe, controlled environment to get accustomed to the new feel.
• Control Familiarization: Ensure you can comfortably reach and operate all controls without strain or distraction.
• Pre-Ride Inspection: Always perform a pre-ride inspection, checking handlebar security, control function, and cable routing.

Maintenance

Regular maintenance will ensure the longevity and appearance of your Klock Werks Klip Hanger Handlebar.

• Cleaning: Clean the chrome finish regularly with a soft cloth and a non-abrasive chrome cleaner. Avoid harsh chemicals or abrasive pads that can scratch the finish.
• Inspection: Periodically inspect all mounting bolts for tightness. Check cables and wires for any signs of wear, fraying, or damage. Ensure controls operate freely.
• Lubrication: Lubricate control cables as recommended by your motorcycle's service manual.

Troubleshooting

If you encounter issues after installation, review the following common problems and solutions.

• Loose Handlebars: Re-check handlebar clamp bolts and ensure they are torqued to specifications.
• Controls Binding/Sticking: Verify cables and wires are routed correctly, free of kinks, and have proper slack. Ensure controls are not overtightened on the handlebar. Lubricate cables if necessary.
• Electrical Issues: Check all electrical connections for proper seating and continuity. Ensure no wires are pinched or cut. Re-check battery connection.
• Uncomfortable Riding Position: The Klip Hanger design allows for some adjustability. Loosen handlebar clamps slightly and adjust the angle until comfortable, then re-torque.

If problems persist, consult a qualified motorcycle technician.

Specifications

Warranty Information

Klock Werks products are manufactured to high standards. For specific warranty terms and conditions, please refer to the official Klock Werks website or contact their customer service directly. Keep your proof of purchase for any warranty claims.

Customer Support

For technical assistance, installation questions, or warranty inquiries, please contact Klock Werks customer support:

• Website: www.kustombaggers.com (Klock Werks official site)
• Refer to the contact section on their website for phone numbers or email addresses.