SuzukiSavage.com - Handle bar controls.

HoustonBussa YaBB Newbies Offline If it ain't fun I ain't doing it -SYCKK Life Posts: 45 SW Houston Gender:	Handle bar controls. 01/26/14 at 16:35:52 Has anyone changed out their controls for non stock controls? What's available out there? What headaches did you encounter? I'm doing a RYCA Motors RR-1 bobber build and would like to change out the controls for a cleaner look. Plus the ones I have are beat up pretty bad.
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houstonbofh Senior Member Offline SuzukiSavage.com Rocks! Posts: 420 Houston, TX Gender:	Re: Handle bar controls. Reply #1 - 01/26/14 at 19:28:44 If you are talking the switch boxes, they break apart easily. I have seen them chromed, and powder coated. I have to say that the gloss black powder coat looked very good! If you are talking levers, look at a later model Boulevard, as they pretty much just swap out.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Handle bar controls. Reply #2 - 01/26/14 at 20:52:29 HB, The tech section is for how to's, questions go in RSD.
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Re: Handle bar controls.
Reply #3 - 01/27/14 at 03:58:59

It is pretty common for "Cruisers" with 1" bars to have big looking controls....not sure why.

I went for a smaller, cleaner look on my Cafe' conversion....also switched to 7/8" bars. I don't believe there is anything that you can just "plug in" to our wiring harness, so if you go to something else for switch controls you will most likely need to do a lot of wiring changes.

I managed to get it done - but it took a lot of looking, scrounging, testing, and adapting. It can be done..............but it is not easy. I have not and will not do a...."HOW TO" on the job. I did have a few nights where this part of the job went over and over in my head while I was trying to sleep.

I have a KLR650 right electrical control spliced into the stock wiring harness plug, a GSXR 1000 right electrical control spliced into the stock wiring harness plug, GSXR 600 Clutch Lever, Honda TRX 400 EX front brake master cylinder, Maguar Throttle....and I made all the cables.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Handle bar controls. Reply #4 - 01/27/14 at 07:19:01 Hey, you Houston guys,, I used to live there.. went to Aldine Jr High,.,
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HoustonBussa YaBB Newbies Offline If it ain't fun I ain't doing it -SYCKK Life Posts: 45 SW Houston Gender:	Re: Handle bar controls. Reply #5 - 01/27/14 at 22:43:00 verslagen1 wrote on 01/26/14 at 20:52:29: HB, The tech section is for how to's, questions go in RSD. Yea.. Put it here by accident. Meant to put it next to my other question that IS in the right place. If an admin wants to move. Cool.. Although this will become technical once I find what works.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Handle bar controls. Reply #6 - 01/27/14 at 22:46:04 We'll be happy to see a full how to on the subject.
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HoustonBussa

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Re: Handle bar controls.
Reply #7 - 01/27/14 at 22:46:18

houstonbofh wrote on 01/26/14 at 19:28:44:

If you are talking the switch boxes, they break apart easily. I have seen them chromed, and powder coated. I have to say that the gloss black powder coat looked very good!

If you are talking levers, look at a later model Boulevard, as they pretty much just swap out.

I'm actually talking a complete swap. Seen some bars, but most are like 7/8", but come with switches, levers and the whole nine.

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HoustonBussa

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Re: Handle bar controls.
Reply #8 - 01/27/14 at 22:49:12

Dave wrote on 01/27/14 at 03:58:59:

It is pretty common for "Cruisers" with 1" bars to have big looking controls....not sure why.

I went for a smaller, cleaner look on my Cafe' conversion....also switched to 7/8" bars. I don't believe there is anything that you can just "plug in" to our wiring harness, so if you go to something else for switch controls you will most likely need to do a lot of wiring changes.

I managed to get it done - but it took a lot of looking, scrounging, testing, and adapting. It can be done..............but it is not easy. I have not and will not do a...."HOW TO" on the job. I did have a few nights where this part of the job went over and over in my head while I was trying to sleep.

I have a KLR650 right electrical control spliced into the stock wiring harness plug, a GSXR 1000 right electrical control spliced into the stock wiring harness plug, GSXR 600 Clutch Lever, Honda TRX 400 EX front brake master cylinder, Maguar Throttle....and I made all the cables.

Oh wow.. Yea.. I was hoping a little more ....er... simpler.. ie buy a complete set and then just figure out the wiring.. I'm more concerned about the reservoirs connected as needed vs the wiring. Although a pain in the.......... ya know... You've done it. But I know I can do that.. Just more worried about keeping the ability to apply brakes.

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HoustonBussa YaBB Newbies Offline If it ain't fun I ain't doing it -SYCKK Life Posts: 45 SW Houston Gender:	Re: Handle bar controls. Reply #9 - 01/27/14 at 22:50:26 justin_o_guy2 wrote on 01/27/14 at 07:19:01: Hey, you Houston guys,, I used to live there.. went to Aldine Jr High,., I moved here about 10 years ago.. Army brat, and then joined the Army, so been all over.. My family is from Abilene TX though.. If you ever have a chance to go there..... DON'T.. lol
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HoustonBussa YaBB Newbies Offline If it ain't fun I ain't doing it -SYCKK Life Posts: 45 SW Houston Gender:	Re: Handle bar controls. Reply #10 - 01/27/14 at 22:51:19 verslagen1 wrote on 01/27/14 at 22:46:04: We'll be happy to see a full how to on the subject. Yea.. Me too.. hahaha
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houstonbofh

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Re: Handle bar controls.
Reply #11 - 01/28/14 at 07:26:12

A bunch of Marauder types have done it, and they are the same parts on the Savage. You have; Clutch safety, brake light, left turn, right turn, horn, kill switch, and start. With some time and a test light you can trace it down, and fab up what you want.

But, the right control also houses the throttle assembly, so if you replace one, you have to replace both.

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Re: Handle bar controls.
Reply #12 - 01/28/14 at 07:54:48

Bar switches? Master cylinder? Gag.

Stainless plate on the frame with 2 toggle switches and the horn button. Front drum conversion. Universal throttle/grip assembly. Still need to swap my mirrors for period correct 30s-50s type.

Still have to order/track down/install close to $1000 in parts to make the thing look right and not be quite so cramped up while riding it.

Awful lot of work for a bike worse less than $500 based on its age and lack of general riding public interest... Roll Eyes

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HoustonBussa

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Re: Handle bar controls.
Reply #13 - 01/28/14 at 23:16:07

houstonbofh wrote on 01/28/14 at 07:26:12:

A bunch of Marauder types have done it, and they are the same parts on the Savage. You have; Clutch safety, brake light, left turn, right turn, horn, kill switch, and start. With some time and a test light you can trace it down, and fab up what you want.

But, the right control also houses the throttle assembly, so if you replace one, you have to replace both.

I've come to the conclusion I can do it. Just going to take some work. Do probably down the line I will do it. I plan on doing both sides and all controls.

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Re: Handle bar controls.
Reply #14 - 01/29/14 at 05:34:13

I can't remember the diameter of the piston in the front brake reservoir - but it is stamped on the housing. You will see a "1/2", or "13", or something like that. That is the size of the piston and you can replace the front master cylinder with anything that uses the same size diameter piston. You can go to places like Dime City and order new master cylinder and clutch lever sets and they will most likely have some brake light switch either built in - or added in the form of a pressure switch installed in the hydraulic line. I used a 2008 Honda TRX 400EX front brake cylinder as it is much smaller and has a switch built in that you can just plug the stock wires into.

The electric controls are a bit harder to adapt - but there are plenty of aftermarket switch sets available, and they just need to be spliced into the stock wiring harnesses.

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