Thought I would share some information and parts resources, just in case someone else wants to do the same project.
2005 Katana 750 - 2" Handlebar Raise
I bought a 12" long piece of 6061 aluminum round bar stock and cut four 2" spacers with a band saw. I used a drill press to drill a 3/8" hole down the center of each one.
I bought a clutch and dual throttle cable kit from VenhillUSA. I was absolutely stunned at how complete the kit was. Everything you need to make quality, custom length cables for your Kat.
http://www.ebay.com/itm/Venhill-Univ...EczAvg&vxp=mtr
So I noticed that the factory cables have a rubber sleeve on them to protect them from abrading on the steering stem, frame rails, etc. I decided to simply cut the end off the factory cable and reuse all of the hardware I could, minus the longer housing and cable. I slid the factory sleeve over the new cable housing so it would be protected like the old one was and then went about routing them and measuring for length.
When I finished I ended up with proper length cables with no binding and routed like the originals were, save for the clutch cable which is now outside the carbs.
I bought new brake lines from Sixty61com. I called and had them add 2" in length. Knowing what I know now, the standard length lines would have worked just fine. The configuration I went with is what they call 2F, which is two lines at the master cylinder, each running directly to the calipers.
http://www.sixty61.com/product-p/cmblf021.htm
The lines are top quality and come with nice banjo bolts and copper crush washers for making everything seal up nice.
I bought the longer stem bolts from BoltDepot.com. With standard shipping, the 4 - 10mm x 1.5mm x 130mm Grade 12.9 socket head bolts and the 4 nylon insert Grade 10.9 nuts cost $16.
The choke cable was long enough as is, once I did a little re-routing.
Anyway, the whole project set me back about $200, but I needed to replace the brake lines so that really didn't count.
I took it for a test drive this afternoon and it is absolutely amazing how much of a difference it makes raising the bars just 2". I plan on doing a longer trip next weekend and I'll report back with the results, if anyone is curious.
2005 Katana 750 - 2" Handlebar Raise
I bought a 12" long piece of 6061 aluminum round bar stock and cut four 2" spacers with a band saw. I used a drill press to drill a 3/8" hole down the center of each one.
I bought a clutch and dual throttle cable kit from VenhillUSA. I was absolutely stunned at how complete the kit was. Everything you need to make quality, custom length cables for your Kat.
http://www.ebay.com/itm/Venhill-Univ...EczAvg&vxp=mtr
So I noticed that the factory cables have a rubber sleeve on them to protect them from abrading on the steering stem, frame rails, etc. I decided to simply cut the end off the factory cable and reuse all of the hardware I could, minus the longer housing and cable. I slid the factory sleeve over the new cable housing so it would be protected like the old one was and then went about routing them and measuring for length.
When I finished I ended up with proper length cables with no binding and routed like the originals were, save for the clutch cable which is now outside the carbs.
I bought new brake lines from Sixty61com. I called and had them add 2" in length. Knowing what I know now, the standard length lines would have worked just fine. The configuration I went with is what they call 2F, which is two lines at the master cylinder, each running directly to the calipers.
http://www.sixty61.com/product-p/cmblf021.htm
The lines are top quality and come with nice banjo bolts and copper crush washers for making everything seal up nice.
I bought the longer stem bolts from BoltDepot.com. With standard shipping, the 4 - 10mm x 1.5mm x 130mm Grade 12.9 socket head bolts and the 4 nylon insert Grade 10.9 nuts cost $16.
The choke cable was long enough as is, once I did a little re-routing.
Anyway, the whole project set me back about $200, but I needed to replace the brake lines so that really didn't count.
I took it for a test drive this afternoon and it is absolutely amazing how much of a difference it makes raising the bars just 2". I plan on doing a longer trip next weekend and I'll report back with the results, if anyone is curious.
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