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Old 10-14-2008, 07:40 PM   #16
Gnarly Adventurer
Joined: Jun 2008
Location: Lake Villa, IL
Oddometer: 201
Finally I get around to posting to the thread...

I installed the Rally Pro's on my bike as well. They look good, they feel very solid, and I'm confident they saved me from having to buy a new clutch lever after this weekend.

The hardest part I needed to deal with was the brake hardware interfering with both the amount the inner mount could come out to the end of the bar AND the brake light switch interfering with the bar itself.

I ended up cutting some of the plastic away to allow the switch to clear and bent the bar to make it a little wider from inside to out. This enabled me to nestle the lever inside the hand guard, but still give me clearance to push the lever out and tap the guard. I'm developing the habit of tapping the guard with the lever while stopped, so I'll notice if that clearance goes away.

I also had to rotate the clutch lever down under the handguard. I don't know HOW you bent it to fit, but at first glance there is NO WAY I can get the lever inside the cup. It didn't seem to matter this weekend though as I had two falls at speed in the sand and the lever wasn't bothered at all, though I do have abrasions on the guards.

I had no problem getting the bar end bolts drilled and tapped for the 8mm acerbis bolts and it all went together really well.

Overall I'm really pleased. I wasn't sure if I'd get them at first, but when I priced out a new lever (some $80 or so I think!) it only made sense to protect them as much as possible.

More pictures of placement, clearance, etc in this album:

These were before the bolts were tapped, so it's all just press fit together in the pictures. I didn't change the placement of the inner mounts at all in final form though.
'09 F800GS (Yellow)
'05 F650GS (Sold)
'04 K1200RS (Sold)
'03 F650GS (Crashed)
(formerly hyperiate)
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