Integrated Gear Indicator & Master Cylinder Mount

The Headache

On a 2000 Kawaskai ZX9R motorcycle, real estate on the handlebar and dash areas is at a premium. We wanted to add a digital gear position indicator, but just doublesided tape to hold it on looked like an afterthought with the potential for cable damage. The goal was to find a "factory-plus" way to house the indicator while maintaining or improving the structural integrity for front brake fluid reseviour.

The Process

We identified a gap near the front brake master cylinder where a consolidated mount could live.

1. Scanning: Using one of our new Einstar Laser scanners, we captured the complex geometry of the handlebar area and the master cylinder mounting points.
2. Modeling: The resulting mesh was imported into Fusion 360. We designed a custom holder that serves as both the brake fluid reseviour mount and the housing for the gear shift indicator.
3. Iteration: We ran a draft 3D print to verify the "air gap" between the indicator and the triple tree, ensuring full lock-to-lock steering clearance.

The Result

After a successful test fit, we moved to the final material print. The final part integrates the gear indicator seamlessly into the brake assembly, resulting in a streamlined, integrated look that looks like a quality aftermarket component that adds modern functionality.