Lower handlebars on '82

[chilidawg]

Make sure, if you do buy a better angle master cylinder, that it has a 14mm piston, that's the only real requirement to operate the 82 twin front discs properly, 83 (linked) front system uses a 12mm.

 

[Ansimp]

chilidawg » Thu Jun 12, 2014 11:07 am[/url]":3vjohbl9]
Make sure, if you do buy a better angle master cylinder, that it has a 14mm piston, that's the only real requirement to operate the 82 twin front discs properly, 83 (linked) front system uses a 12mm.

I am finding smaller diameter is giving me more brake pressure and better feel( more progression) :yes:

 

[chilidawg]

All I found was that smaller diameter, meant no brakes.

 

[Ansimp]

As you can see by my ride videos from last Saturday the Rats Nest has brakes!!
viewtopic.php?f=31&t=7946&p=120359&hilit=Rides#p120354

 

[canuckxxxx]

I would think that, as long as there is no air in the system, the smaller piston would work. And especially since other have done it successfully.

Perhaps if you had some runout in the rotors so that the pads get pushed out more than normal in their rest position. Then when you apply the brakes the small piston cannot supply the volume needed to move the pads against the rotor.

Brian

 

[esturdivant]

further on the cables / lower bars topic..... on my 82, i've been having a hard time finding (without buying a ton of different ones) the right throttle cable. also, I replaced the factory RH start switch/cable/tube housing with a more modern, compact switch. So I have been looking for the right setup. tried a ZX6 setup, bought used from ebay, and it is a few inches too short. After searching, found a DRZ400 dirtbike setup that I think will work well. the throttle cable/tube housing is perfect for what I need. the cable length seems perfect from my measurements ~37/38 inches with my superbike low rise bars. the new cables are on the way from ebay. the housing is the same housing from several suzuki/kawasaki models. I'll post up some pics when all sorted..

 

[canuckxxxx]

Actually, today I shortened up the pull throttle cable on a suggestion from Joe Drum. I have a single carb. setup on my '82 and the throttle cables come in from the front so they were way too long.

As you know the pull cable has a screw adjuster about 2/3 down it's length. I cut the carb end off and unscrewed the cable housing from the bar end and slid it off. Separated the housing at the screw adjuster. Cleaned the housing by blowing WD40 through and then air. Took the threaded part off the short piece of cable housing, that I did not use, and screwed it into the longer housing that I did use.

Now the tricky part of putting a new end on. I cleaned the end of the cable with lacquer thinner and then methyl alcohol. I even separated the strands to help with the cleaning. Bought a 1/4" brass bolt, cut it to the length of a cable end, and drilled a hole through it the size of the cable. Put flux on the cable end and the brass piece and soldered the brass thing onto the end of the cable using a big old soldering iron.

Only cost me 54 cents for the bolt.

Now I have to do the other cable

Brian

 

[canuckxxxx]

esturdivant » Sat Jun 21, 2014 8:23 pm[/url]":1lswr5et]
further on the cables / lower bars topic..... on my 82, i've been having a hard time finding (without buying a ton of different ones) the right throttle cable. also, I replaced the factory RH start switch/cable/tube housing with a more modern, compact switch. So I have been looking for the right setup. tried a ZX6 setup, bought used from ebay, and it is a few inches too short. After searching, found a DRZ400 dirtbike setup that I think will work well. the throttle cable/tube housing is perfect for what I need. the cable length seems perfect from my measurements ~37/38 inches with my superbike low rise bars. the new cables are on the way from ebay. the housing is the same housing from several suzuki/kawasaki models. I'll post up some pics when all sorted..

Good tip on the DRZ cable lengths. What are the lengths of the ZX6 cables? Because of my single carb setup I need very short cables.

What switch/throttle did you use for the right side? Was the wiring hard to change? Are you going to change the left switch assembly too?

Thanks
Brian

 

[esturdivant]

The ZX6 cables are about 31-32 inches or so. they're currently on the bike so I cant get an exact measurement... my bars are about a 2" rise and I thought the ZX6 cables would be long enough, but when I turn the bars left, the cables appear to bind a bit. So I finally found the dirtbike cables and by my rough measurements they should fit the bill. The whole reason for me doing all this was that I wanted a cleaner kill switch - so maybe too much effort for such a little detail, but that's what I wanted. here's a pic of the new switch. not sure what the fit is, but i kept trolling ebay until i found one i liked.

 

[esturdivant]

Here is the switch.

 

[esturdivant]

I do also plan on replacing the LH switch - preferrably with one from a hayabusa/bandit/gsxr or something like that because i want flash-to-pass headlight function so i can wire in a garage door opener to the FTP button. again, maybe it's overkill, but thats what i want and plus it'll look a little more modern. going for a naked, updated, stripped down bobbber-ish look with this 'wing, if that makes any sense

 

[Ansimp]

Nice upgrade to the switch gear :good:

 

[canuckxxxx]

esturdivant » Sun Jun 22, 2014 8:39 pm[/url]":2y6k5umb]
Here is the switch.

Looks excellent...much cleaner than OEMs. Is the switch assembly and the throttle separate pieces?

Brian

 

[esturdivant]

yep - the kill switch and the throttle tube/housing are separate items - that's the whole reason I'm having to search for the proper length cable - the stock housing is built into the kill switch.

 

[esturdivant]

ok - the DRZ cables got here today and i got them on. they're the perfect length. so my throttle assy consists of a housing from a sv1000 (although this same housing fits many suzuki and kawasaki models) and cables from a DRZ400 dirtbike. i suppose the housing would also fit the DRZ since it's a push-pull set and they have to fit in the housing to work... see above pic for the housing. my bars are much lower than stock 82 aspencade - basically 2" rise. don't have the cable bracket made up yet, but I was just going to bend some thin bar stock in my vice and bolt to the same bolt right where the radiator fan shield bolts to - there's about 3/4" of bolt left and i think i can fit the bar and a nut/lockwasher in there.

 

[canuckxxxx]

esturdivant » Wed Jun 25, 2014 10:40 pm[/url]":11nr8hr3]
ok - the DRZ cables got here today and i got them on. they're the perfect length. so my throttle assy consists of a housing from a sv1000 (although this same housing fits many suzuki and kawasaki models) and cables from a DRZ400 dirtbike. i suppose the housing would also fit the DRZ since it's a push-pull set and they have to fit in the housing to work... see above pic for the housing. my bars are much lower than stock 82 aspencade - basically 2" rise. don't have the cable bracket made up yet, but I was just going to bend some thin bar stock in my vice and bolt to the same bolt right where the radiator fan shield bolts to - there's about 3/4" of bolt left and i think i can fit the bar and a nut/lockwasher in there.

Thanks for all the good info. Do you have any pics of your bike with lower bars...sounds like an interesting machine.

Brian