RD350 Replica Handlebar Installation on Electra 5s (CI)

With greased hands, it's kinda tricky to take photos, still managed to get some essential ones. These are sufficient for anyone to know what to expect from this DIY task.

Allen Key #6 for the bar-end weights

Two screws and the left switchgear come apart. Notice the tiny hole on the handlebar, a plastic from the switchgear fits there. It restricts it from rotating around the bar when switches are pushed.

This I swear was the toughest part and was the least significant one in the grand scheme of things. So when it took more time than I was ready to spend for this, I went ahead and did this...

This!! Gotta get a new set of grips now :)

[Update: Try this for grip removal instead]

Loosen the adjustment tube at the end of the clutch cable near the handle bar and get the clutch cable out from its groove. Bit tricky for first-timers but have patience and don't damage the cable by any chance.

Right-side switch gear with the throttle assembly

Carefully remove the throttle cable from the hand grip slot.

I was lucky to have a neighbor lend me his size #17 spanner. I am gonna add it to my tool kit now.

RD350 (replica) handlebar compared to Electra 5s stock handlebar

These two bolts below the handlebar would need size #14 spanners and are fairly easy to take out or put in.

The groves which restrict the handlebar from rotating once tightened, are very faint on the RD350 black model. So I tried to use the saw blade from my Gerber to etch some lines. Later got some cut marks done by a mechanic on the roadside using a hammer and a chisel. Hope this holds up.

Before tightening all 4 screws, sit on the seat and adjust the bar to your preferred position.

Slide in the mirror and clutch assembly before putting on the switch gear.

Align the switch gear to stay exactly on the hole on the bar, the plastic bit should fit right inside.

Test all the switch operations once. Note: I had to remove the fuel tank to get access to the cables, which were required to be pulled by 2-3 inches more to fit this new extended handlebar.

First, put the small drum into the grove and then use some force (and pull and release trick) to bring the clutch cable to its path.

The adjuster screw seen here needs to be slotted in and then screwed into the lever hinge.

Final look. Yesss!!

Totally it took 2-3 hours to complete this. I am yet to add the zip ties, as I don't have black ones with me. That would complete the setup. In case you have any queries on this post/steps, feel free to post them in the comments.

Update [19/04/2015]: Here is a sneak preview of the new look:

Confidence comes from experience, so get your hands dirty in things you like.

Cheers !!,

Sid

Project: Enduro Type Handlebar

So far I have been really pleased with the stock handlebar on my Electra 5s (CI). However, during my Leh tour, there were times when I felt stress on my arms, mostly shoulders, and I faced difficulty in maneuvering my loaded bull on tricky mountain routes with stones and gravel. Though being 'fit n strong' (ahem!) helped me manage those patches, definitely I wouldn't like to keep stressing my limbs every time I ride through such terrains. As they increase the possibility of an injury. As the trip provided tons of first-hand experiences with pain being the least exciting of all, I almost forgot about it after coming back. After my return last year in August, I have done some serious off-roading, during my ride to Mandalpatti Peak. Where I and a buddy took a cycling trail through the mountains. It was a hell of fun doing off-roading(post coming soon). Only a few days back I was checking online for some touring mods on my ride and all the mental notes I had taken during the Leh trip came right back. And here I am with my first mod project: 'The Best Touring handlebar for RE Electra'.

Best Handlebars for Highway Cruising:

So far the comfiest bars I have used were on the big Harleys (partly the comfort was due to the punchy torque and comfy/plush seating). Among bulls, Thunderbird I believe has the comfiest handlebars as stock, as they keep your arms flexed at all times and hence add no stress on long hours of highway cruising. But there is a catch, the cruising bars are not confidence-inspiring for dirt/off-road/aggressive riding, as it provides a more pulled-back seating posture. This means it does not give you that forward-leaning stance, that off-road riding requires. Now coming to the looks of those bars, they mostly go well with laid-back cruiser-looking bikes like Thunderbird (or the mighty RE Lightning 535 of yesteryear). Electra however is a totally different deal. It comes as a retro-looking, blank canvas and it inspires imagination in stock form. Actually, the design is very basic and that is what excites buyers (mostly seasoned bikers), to think about how they can customize and make it unique. It can be given any look based on your taste. So far I have kept mine looking like a chromed cruiser with a bit of a vintage look and feel with the stock handlebars. However now after my extensive off-road riding (which is what most of the Leh-Ladakh route can be termed as), I am very much looking forward to trying out an enduro/rally setup on my bike. More on this setup in a later post. For now, let's stick to the project at hand. 

Best Handlebars for Adventure Touring (Cruising + Off-roading):

Now I did my search and read around to know which would be the best handlebar for my needs (touring + off-roading) at the moment. After digging around for a few days, I could zero in on the 'RD350' handlebar with a center rod. It's not the first time I am seeing or hearing about this particular design. It's been there since Enfields are being customized (which is like forever!). But what convinced me for this one is the fact that it's the most commonly used handlebar on all rally/trail fields, without exception.

DISCLAIMER: Images below are not mine and owned by their respective owners. I have used them here for reference only.

 I could guess the reason why. On mud/dirt/gravel this gives that upright stance to maneuver this heavy bike. And the center rod along with the bar-end weights takes care of the characteristic vibes generated by the bull. This bar I could feel is taller and a bit* wider than the stock handlebar, which will make cruising a bit more enjoyable am sure. Well, these all are my expectations, based on my experience with similar handlebars. After riding for a while with this new set, I will definitely post an update.

The Hunt:

For this mod, instead of me going out hunting for the accessories, I posted a query on one of the RE pages on FB. Though I wasn't expecting much, some people like Jijo, Hitesh, and Anirudh came forward with suggestions and their experience with the bars, etc, which turned out to be very informative. If you guys reading this post, a big 'Thank you'.

Keeping a copy of the thread in case you are walking the same path while modding your steed.

The Purchase:

Initially, I thought of visiting JC road with the bike and getting the job (purchase and fitting) done there. Then I got free from work a bit late and didn't have time to drop my car and pick up the bike to visit JC road. So directly drove there and picked up a mint-looking RD350 rally-type handlebar with center rod and end threaded holes (to fit bar-end weights) for 280 bucks. Seeing the (perceived) quality of the build of this bar, I would say I am impressed. It feels sturdier than I had expected and the fit and finish look good. Have a look for yourself.

Rider side (rear) view

Front side view

Hole with threading for fitting the bar-end weights

Plastic sheet wrapping on the whole bar to protect the paint and finish. Nice touch! :)

As tomorrow is a shutdown in the city ('Karnataka Bandh' due to the Kaveri water dispute), mostly all shops/garages will remain closed. I had to visit the bank for some work, but that's not gonna happen now. So why not get my hands dirty and get this rod fitted myself :) 

In the morning I will get to it and if possible will try recording the process and 'gotcha and will post the updates here. So stay tuned!!

Update [18/04/2015] : Today I swapped the handlebars. Quite a task but I enjoyed it thoroughly. Steps are available in a new post, which you can access here. This evening I finally took the bike out on the streets, both busy city roads (still much less than peak hour traffic though) as well as open roads where I rode a bit faster (within allowed limits of course). Here are my first impressions:

• Shoulder and arms quite relaxed all through the ride (compared to stock)
• It feels easy to filter through tight spaces between big vehicles moving slowly on city roads (this was difficult with stock handle, as when riding slow it use to take a lot of effort and strength to maneuver it)
• Due to this newfound agility and effortless maneuvering, I think I was riding a bit faster than usual and kinda aggressively (compared to my usual riding style). I am sure this is more due to the excitement of the new setup and will mild down as I get back to riding more.
• The bike no more feels like a cruiser from the rider's PoV. It looks and feels more like a dirt/enduro bike (not sure what else I was expecting here! lol)

I think a long trip would help me in evaluating the new setup in detail. Will try and update that when it happens.

Update [05/05/2015]: Completed a 1200 KMs trip through Tamilnadu and Kerala and could confirm the new handlebar is a gem. Lots of ghat section riding too and really happy with the way the motorcycle handles now with the new setup.

Ride Safe & Ride Far,

Sid

Weekend - late-night-after-the-movie shot

Yep, the pillion back-rest is added due to popular demand:) Here is few more pics of the same at my building parking lot..

Rear view of the saddle bags and the back-rest

Those of you wondering, it costed me 700 bucks from an Enfield Genuine Accessory shop.

Ride Safe & Ride Long,

Sid

My Steed got New Pair of Saddle Bags

Royal Enfield Wheels - 19" or 18"

While looking online for new set of shoes (read tyres) for my Enfield, came across this ad in

http://www.hitchcocksmotorcycles.com/accessory-frame-tyres

A year and half back when I was digging online forums before buying a Classic 500, I had come across this news, but got suppressed as sales were high and definitely as a owner you just can't keep talking about a design flaw which can't be changed in any way. But I got the hint that the classy design was not a result of a thoroughly tested prototype, it was rather a cosmetic re-innovation, which somehow worked. Nevertheless Classic 500/350 is a good bike, especially as it carries Royal Enfield DNA. And it's great to know that it can be stabilised by using bigger wheel size.

Personally am happy to know that 19 inc rim size has it's own advantages, which soothes the pain caused while trying to find a set of decent tyres. Speaking of which I come back to the point I was writing this post. Yep am looking for good (*subjective*) tyres and will post as I find some good options in Bangalore or online.

Keep Checking Back,

Sid

Bullet Mod - Customised Stock Seat

This is a quick update. I was fiddling around with the idea of a split seat for a while, but was not able to finalise one. As I have shifted my focus to the maintenance side lately (remember Zen.. ), I though of getting the existing seat re-conditioned (replacing the sponge n stuff). Upon a visit to a seat maker, got to know that the seat base is pretty rusted and it's not a wise idea to spend money on that. After seeing the amount of rust under the seat, I decided to get the base plate replaced with a new one. A new Electra seat (with cushion and cover) costs 1300 bucks (I guess). I wanted the contours to be customised, so decided to do the following:

1. Get a new base plate

2. Get the seat built from scratch (or modify a stock base foam layer)

3. Customise the contour as per my requirements

4. Select a good skin (rexine)

[5]. Pick a set of split seats later [optional]

I got it done today after office. Here are some pics taken during the make over and few after it's complete:

just after the seat is removed. It's dust on chrome. It was looking great after a bit of wiping with a cloth, but alas my mob battery was drained out by then, to take any pictures.

I loved the way the bike looks here. I could think of a custom bobber or (The) Indian type custom built ride based on this frame. Or simply a set of retro styled leather split seats may be;)

Side View: You can notice the contour I was talking about. The level from the front goes like: Mid High > Too Low > Too High.

If you hadn't noticed, the chrome rim(they call it bead I guess) which was around the seat is removed now. It was nice of that fellow to put a leather/rexine trim around the seat, which is subtle yet looks quite nice. I think I have seen such a thing on older Royal Enfields.

I picked a dimple textured rexine which was quite thick and soft. It feels great to touch, compared to the smooth black rexine that the bike had earlier.

Rear grab bar is removed as it's height is falling short due to the heightened rear seat cushioning.

The seat looks awesome and feels good too. Though not too soft compared to the old seat. However, thats a good sign considering after some use it is expected to soften more. This whole thing did cost me 1350 INR (roughly 25 US$ in current exchange rate of 54 rupee/$).  I will need that grab bar to pull the bike off parking or from any low ground, so will check out at the Bullet Accessory Shop in the coming weekend. 

Now as the new seat is in place, I think I should do a long ride to test it. You must be thinking I just need a reason to ride!! Well...you bet;)

Ride Safe n Ride Far,

Sid