Trail Tech 1 1/8" HANDLEBAR CLAMPS 030L-Y02F - Manual (Page 2)

POLARIS PREDATOR INSTALLS:
Use the stock nuts off the bolts going into the steering stem for use with the bolts we provide. Also, when removing clutch lever assembly off of
the stock bars, make sure to only remove the one screw on the front side of the assembly (it is covered by a black cap). Torque value for the
steering stem bolts is 10 ft. lbs. The choke fits into the deeper hole in the clamp.
HONDA TRX450 INSTALLS:
There are threaded bosses that align the part to the stock stem. Place the clamp in the cover and verify
that the clamp goes to the bottom of the cover (to make sure nothing is in the way). With the clamp
inside the cover, place both parts on the stem and slide it around until the bosses drop into the holes on
the stem. Use the stem bolt washers, and tighten the two M10 bolts. Loctite can be used if desired. The
4 non-threaded holes in the bottom of the clamp are there to reduce weight, not for installing the clamp.
When installing the High Bend X-Bar:
The brake cable will be too tight without some adjustment. To get more slack in the cable, loosen the
bracket holding the cable under the front plastic nose piece. The cable can be moved further through
the bracket, though it may be necessary to cut the protective sheath first, as shown to the right. TRX450 PROTECTIVE SHEATH
SLICE LOCATION
KAWASAKI KFX700 INSTALLS:
Trail Tech KFX700 bar clamp and dashboard parts are designed to mount directly on top of the stock lower
perches, which are welded to the steering stem.
DO NOT REMOVE THE LOWER PERCHES.
The KFX700 choke assembly must be trimmed so everything will fit on the bars. See picture to left for
trimming location.
The KFX700 has two locating holes in the stock bars to hold assemblies in place. Follow instructions on
page 1 for assistance with making locating holes in new X-Bars.
KFX700 CHOKE ASSEMBLY
TRIM LOCATION
2
HONDA 250 / 300 / 400EX ‘01-05 INSTALLS:
To Install Bar Clamp & Cover:
1. Remove stock handlebar and clamp.
2. Break off front brake line clip.
3. Take left plastic side panel off.*
Use a screwdriver to gently lift heads up off all 5 clips.
4. Unscrew choke clip from carburator
(located on left side of carburator, under the seat)
and remove choke cable from bike.*
5. Drill 1/2” hole in hood plastic.*
See drawing for choke cable mounting location.
6. Install choke cable in drilled hole and reconnect to carburator.*
7. Trim indicator rubber boots - take notch off.
See drawing for boot trim location.
8. Install indicator lights and key switch into cover.
9. Install cover, clamp and bars normally.
INDICATOR BOOT
TRIM LOCATION
CHOKE CABLE DRILL
AND MOUNT LOCATION*
*Not all models require choke relocation
To Install Bar Clamp & Cover:
1. Remove OEM handlebars and OEM clamp.
2. Remove all three indicator lights from OEM clamp.
3. Remove plastic hoodskin panel.
4. To gain length for indicator lights to route to stem cover: disconnect the black connector
going to them (follow wires down under hood, disconnect connector right below where the
bundle is zip-tied to metal bracket) and re-route connector behind frame tubing instead of in
front of it. (The horizontal tubing right where stock light bracket bolts to frame.)
6. Brakeline:
• Use an 8mm socket to loosen the brakeline from the frame under hood.
• While standing on the right side of the bike, turn the bars all the way to the right.
• Tighten the 8mm bolt back down.
• There should now be brakeline clearance for use with Trail Tech clamp.
7. Insert indicator lights into the three holes on the Trail Tech stem cover. When installing
the stem cover, be sure that indicator light wires go down through the center, rather than
around or under the clamp attachment bracket on the stem.
7. Install Trail Tech cover, clamp and bars normally.
8. Re-install control assemblies and grips onto handlbars. Replace OEM plastic hood.
SUZUKI LTR450 ‘06-07 INSTALLS:
There is a bend in the aluminum bar clamp. It
should face toward the front of the quad.
Backwards installation will cause the control
cables to not be long enough during cornering.