C spec handlebar conversion - No extensions required

[lunkhead]

I do Amazon whenever possible.
1.438 in. Long, .625 in. I.D., 1.125 in. O.D.

https://www.amazon.com/Energy-Suspension-9-8107G-Hourglass-Bushing/dp/B000CN9D3K

[Sdaniels]

Picked up a set of shock bushings for a 1994 Saab 900 from Autozone.  Part # 9.8107G.  About $8.  Used a c-clamp to press them in after spraying with WD40.  Just waiting for the risers to arrive & the clubmans will go on.  Holding the clubmans up to the stock clipons, it looks like a nearly exact match to the current dimensions with 2" risers.

[lunkhead]

Does the hole look straight like it isn't being pinched more in the middle? Did the diameter go down from 5/8"?

[Sdaniels]

The hole is definitely being pinched some.  A 12mm bolt passes through it with just the slightest bit of side play.  I had a sleeve I planned on using, snug fit in the bushing before putting into the triple, but not after.

[Sdaniels]

I think the risers I have coming use a 1/2" bolt so that'll fit just a hair tighter than a 12mm.

[lunkhead]

I wouldn't have the threads bearing against the bushing if that's what you're saying but you're not using bars with much leverage so give it try. I like to know what diameter the SR400 uses.

[srinath]

The correct way to install a bushing in your house instead of a big $$$ machine is to use the split hourglass machine - I cant tell you how many of these bushings I have fabbed and this and that ...
Is it possible to get it right with the 1 piece and hammer away ... yea ... but if it was my bike - I'd copy the suzuki or a myriad of other bikes that had split bushings unless I had a big bertha press that will keep it lined up - no need for big force, but you want it true with pretty high accuracy - maybe a degree or 2 is ok.
Cool.
Srinath.

[Sdaniels]

I wouldn't have the threads bearing against the bushing if that's what you're saying but you're not using bars with much leverage so give it try. I like to know what diameter the SR400 uses.

Maybe the bolt is shouldered...if not, a couple of wraps of tape would keep the threads from chewing up the bushing.

[lunkhead]

SR400 riser part # is 4AA-23442-01-38. Cap is 4H7-23441-01-38. Bolt is 91314-08035-00. Top washer is 90209-12008-00. Bottom is 90201-10026-00. Nut is 95617-10100-00.

Looks like the riser post is 12mm diameter and the threads are 10mm. Top washer 8mm thick and bottom is 2.6mm. Add a little squish...

For a Part Number in the format XXXXX-XXXXX-XX

These are Hardware (fasteners). they all start with a '9' and end in '00'. - 9XXXX-XXXXX-00

9XXXX-XXXXX-00
The second and third digits tells us what type of fastener:

0 - 'various'
1 - bolts, cotter pins
2 - screws, nuts
3 - oil seals, O-rings, bearings
4 - spark plugs
5 - bolts, nuts
6 - ISO bolts
7 - ISO screws and nuts

9XXXX-XXXXX-00
The fourth and fifth digits tell us what material/surface finish (i.e. chromed).

9XXXX-XXXXX-00
Digits six and seven give the diameter (inner or outer) e.g. 08 would be an M8 size.

9XXXX-XXXXX-00
Digits eight, nine and ten are the length (except for '901' bolts for some reason)
There are also standard fastener types...e.g.
90105-XXXXX are Washer based bolts
90116-XXXXX are Studs
90401-XXXXX are Union bolts

99999-XXXXX means that a part has been superseded by a kit.

[Sdaniels]

Are you sure about those bushings?  They don't look tapered at all.

[lunkhead]

I wouldn't use the SR400 bushings. Just everything else with the 9.8107G bushings. I'll edit them out.

[Sdaniels]

The correct way to install a bushing in your house instead of a big $$$ machine is to use the split hourglass machine - I cant tell you how many of these bushings I have fabbed and this and that ...
Is it possible to get it right with the 1 piece and hammer away ... yea ... but if it was my bike - I'd copy the suzuki or a myriad of other bikes that had split bushings unless I had a big bertha press that will keep it lined up - no need for big force, but you want it true with pretty high accuracy - maybe a degree or 2 is ok.
Cool.
Srinath.

I wasn't having much luck with the hammer & I thought about cutting the bushings in half before the c-clamp idea...it wasn't as difficult as I'd imagined keeping the bushing straight while twisting the bolt.

[Sdaniels]

I wouldn't use the SR400 bushings. Just everything else with the 9.8107G bushings. I'll edit them out.

gotcha

[srinath]

I wasn't having much luck with the hammer & I thought about cutting the bushings in half before the c-clamp idea...it wasn't as difficult as I'd imagined keeping the bushing straight while twisting the bolt.

I thought you hammered it in.
The cast hole atleast in mine has a ridge in the middle. I'd think it will take a bite out if the bushing as I install it.
Well we wont know till we pull it out ...

Way back in 94 when I was flying and had to carry a suit on the plane - believe it or not, there were no zippered up suit carriers back then, I had my suit in a plastic drycleaners bag, the airline gave you a cardboard thing and they stuffed the suit from the top - only way to do it. Crumpled mess. On the way back they tried to do the same thing - I stopped them and I stuck my hand through the top and made her hand me the hanger from the bottom, all the while she said we put 1000's of these in ... and I simply told her, that's great, I have taken 1 out.

The split ones dont have to ride over that casting ridge and are installed top and bottom - no force needed.
Cool.
Srinath.

[7udro]

I am in front of my PC with my Superpro mount bush kit.  A 7/8 highway handlebar arrived today form germany...


Can I ask you whyTH you did ruined the sticker instead of just drilling it.....