21 Tuono V4 ProBrake Clip-Ons Install - Part 3
Channel: Moto Jim
Date: 16/02/2023

Tools needed to remove old Grips:
1. Long Philip screwdriver
2. Can of brake cleaner
3. M5 Allen (hex) key to remove end bar knobs
4. 24mm wrench to remove counterweight inserts
5. Patience and lots of time dedicated for this DIY.

At this point, decide if you want to go with buttons/switches controls (JetPrime or CNC brands) for the left and right hand sides. Note, if you go with a switches, you will be able to get rid of that traction adjuster and be able to use a standard grip for the bar. If you have gone with end bar mirrors, decide also if you want to get rid of the ugly M8 holes left behind from the old mirrors.  Decide also if you want to drill and tap the end bars to fit the OEM counterweight inserts.

Replacement Parts:
1. New Grips
2. If keeping perch with M8 holes, get these holes covers as they are the best: (https://www.af1racing.com/Mirror-Hole-Plugs-PAIR)
3. If getting rid of the perch with M8 holes, get the following:
    1. RSV4 OEM Aprilia Clutch Lever w/Perch #2B003552 (https://www.af1racing.com/OEM-Aprilia-Clutch-Lever-wPerch-2B003552)
    2. RSV4 OEM Aprilia Front Master Cylinder Clip/U-bolt #2B007077 (https://www.af1racing.com/oem-aprilia-front-master-cylinder-clipu-bolt-2b007077)


Tools needed to prepare new bars:
1. Drill template (https://www.af1racing.com/LSL-Drill-Jig-for-78ths-Handlebar-5mm-Hole)
2. 1/8” drill bit for the traction adjuster. 
3. M4x07mm tap
4. 16.5mm Drill bit for the end bars (https://www.amazon.ca/gp/product/B082CWMWGC/ref=ppx_yo_dt_b_asin_title_o05_s00?ie=UTF8&psc=1)
5. M18x1.5 Thread Tap for the end bars (https://www.amazon.ca/gp/product/B01CHRFS96/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1)

Step 3: Drilling and Tapping the Pinholes & End-bar Inserts

There are a total of 4 screws (#20 Torx head) for the control groupings but only one needed drilling for, the traction adjuster.  Left hand side (LHS), from end bar to the centre, has the traction adjuster, the menus control grouping and the clutch perch (no drilling necessary for this). The right hand side (RHS), from end bar to centre, has the throttle control, the Starter/Kill Switches, and the brake master cylinder perch/clip (no drilling necessary for this). The bolt sizes are as follows:

* LHS traction adjuster = RHS throttle control = 1/8" or 3.3mm drill bit size for tap size M4x0.7mm thread.
* LHS control grouping = RHS starter/kill switches = 6/94" or 4.2mm drill bit size for tap size M5x0.8mm thread.
* NOTE. You only need to drill ONE hole and that is for the traction adjuster on the LHS. Drill and tap the hole while the handle bars are mounted and secured in place to get good leverage.
* Make sure you use a filer ad file down the rough edges.

NOTE: Use this template for exact location for the pinholes if you want to drill them all for future use. If using the template, this would be your Step 2: https://www.apriliaforum.com/forums/showthread.php?359446-Rizoma-handlebar-mods-template-for-drilling-the-holes-for-17-20-Tuonos

* The end bar has a 1/2” or 12mm inner diameter I believe. It’s okay to drill it using the 16.5mm drill bit. Be gentle and slow and watch out for kickbacks. Make sure you place the drill bit absolutely centre. Drill in for about 3/4” to 1” deep.
* Use the M18x1.5mm tap and hand tap it. Do not use a drill. You’re working with aluminum so that should be easy.
* Empty the shavings from the drilling and tapping.

Final Inspection and Tight Down

I did not use lock-tite for any of the screws. Hand tight them all down but be careful not to over torque and strip the bolts/threads. This is aluminum you’re working with.

Check again to make sure everything is clear at max left and right turns.

Remember to re-tighten the screw after a long ride.