I just bought a set of 1989 clip-ons, don't have them yet, being shipped currently. One of the bars is bent, The bar is bolted on so it can obviously be replaced with another. My question is, where could I get a replacement bar, or is it just 7/8" aluminum in which case I could just cut a peice of similiar wall thickness and use that? If it isn't 7/8", anyone know what size will work?

I have '89 clip-ons on my '92.  Yes it is 7/8 bar.  You will have to drill a notch in it to keep it from spinning in the clip.  Otherwise you can use any 7/8 bar.

DLW

thanks, looks like I will be cutting some stock. I think I will just make two bars even though only one is bent, I will probably make them thicker so they feel more stable.

Hi there,

Each bar is indeed 7/8" OD seamless tube, about one foot long. 

I suggest seamless 316 marine grade stainless tubing .875 OD .125 wall available here at Online Metals:

http://www.onlinemetals.com/merchant.cfm?id=902&step=2&top_cat=0

316 stainless will not rust, and is significantly less likely to bend in a drop.  I crashed my bike from 40 mph while playing around on a concrete airport ramp and did not bend the bars a bit.   

you think it is necessary to go that thick? I was looking at 1/16" 6061 aluminum

suzuki does still sell the bars as I just picked up a new set from them

do you mind me asking how much they were. I figure I can order the metal for less than 15 bucks

Stock suzuki bars are more than $15 for sure...lol

Anyways 1/16" is great if you are looking to shave some weight, but I would recommend just getting some 7/8" seam welded tubing in like 0.090" wall thickness and you will be good. Then do the cut using the edge of a grinding wheel(i know you are not supposed to used the edge but I am still in one piece) to make the cut. Then cleaning it up with a round file. Worked for me.

sounds good, I'm at college so I have access to a nice machine shop with a cold saw(chop saw with constant lubrication for cutting THICK metal), I was mainly concerned with wall thickness, I think you have all convinced me to go with a thicker metal, no need to save a little weight and risk safety.

glad you can create such a thing.  the closest I have access to is a freakin brake lathe and if I"m lucky an air cutoff saw.

what bar is bent as I have my old ones still and the right hand bar is striaght, also yes they were more than $15.00 price from suzuki was $32.37  CDN each

my right bar is bent

your welcome to have my old ones you just have to pay the shipping

sure....tell me how much and where to send it to...and thanks a lot

Quote from: pjm204 on October 17, 2007, 03:18:21 PM
you think it is necessary to go that thick? I was looking at 1/16" 6061 aluminum

Certainly.  The stock bars are around .100" wall. 

I suggested seamless tube as it is symmetrical.  Welded tube is not symmetrical and may not fit in the clamps correctly.

Be sure that the blade on the cold saw is sharp.  If it isn't the stainless will work harden and strip the carbide clean off.   

Looks like you have it sorted though.   

I need your zip to get a shipping quote

my zip code is 18015

I'm curious, i just got a set of 89 clip-ons and I was trying to remove the bars from the clamps and it looks like the bars were kind of "shaved" down on the inside, like it's not just a straight bar of steel.  I assume they're stock since they have the little threaded insert for the bar ends, but who knows.

anyone know if these bars are stock? 

relatedly, any 7/8" will fit then?  thanks!

More info on what you mean by "Shaved" please.

Kellehar, find out how much shipping would be? thanks