Apes for my Lo
Throttle cable
Brake cable
Wire extensions
Brake fluid
Trans fluid
Cable lube
Trans cover gasket
Derby cover gasket
Exhaust port gaskets (pulling exhaust is easiest way to get to trans cover off the trans)
Urethane riser bushings (a must)
New Grips (at least a replacement left grip if you plan on staying stock)
Shop Service Manual
New mirrors/risers are up to you. Stock ones will usually work
Make life easier and get the Burly kit.
Get ready to spend 7 to 10 hours working on this depending on your skill level. A dealership will quote around 8 hours. Took me 9 and I feel I'm pretty good at working on bikes. I did not pull my exhaust and I spent an extra hour working the trans cover.
Throttle cable
Brake cable
Wire extensions
Brake fluid
Trans fluid
Cable lube
Trans cover gasket
Derby cover gasket
Exhaust port gaskets (pulling exhaust is easiest way to get to trans cover off the trans)
Urethane riser bushings (a must)
New Grips (at least a replacement left grip if you plan on staying stock)
Shop Service Manual
New mirrors/risers are up to you. Stock ones will usually work
Make life easier and get the Burly kit.
Get ready to spend 7 to 10 hours working on this depending on your skill level. A dealership will quote around 8 hours. Took me 9 and I feel I'm pretty good at working on bikes. I did not pull my exhaust and I spent an extra hour working the trans cover.
Trans fluid you can get away without as well. Just park the bike with a piece of wood under the tires like a 2x8 or something similar. Then when you put it on the stand it should lean over enough that you won't lose much, if any, fluid from the trans when you pull the side cover. You definitely should replace this gasket though, as it is paper.
Also, if you don't have stock exhaust, you may not need to remove the exhaust to pull the trans side cover. I did not need to.
As for cable lube, most cables should come pre lubed when new. My magnum shielding cables did.
Factory grips should come off, even the left side. Just twist the **** out of it and it should come. I did not have to cut my stock left grip off on my Breakout.
As for risers and handlebar diameter, that is up to you. Your stock risers accommodate a 1.25" diameter clamping surface. Most handlebars are 1" at the clamping surface, even the 1.5" bars from Carlini, etc. Pay special attention to what diameter the bars are at the clamping surface. If you find bars you like that are 1.25" then great, if not you will need to swap risers, or use a 1" to 1.25" adapter from Wild 1.
Good luck, it isn't as hard as it sounds if you have any wrenching experience.
The service manual tells you to drain the trans fluid before popping off the cover. Also, when I installed the new clutch cable, I performed a clutch adjustment to ensure everything was setup correctly. Actually adjusting the rod could be skipped.
I never tried to get the left grip loose. I'm guessing a mild amount of heat could loosen the glue grip. I did try this one a few bikes in the past and never had luck with it. When or if I ever sell the original bars, I'll include the stock grips.
Cable lube... might be lubed but with what? I like the lube i use and it's a small amount of insurance.
Exhaust...Mine was stock at the time of handlebar change and I worked around it. If the exhaust is aftermarket, it could likely be easier to remove the cover. That's a decision the OP has to make. Also, if it's the first time the exhaust is off, he could likely reuse the old gaskets without any issues.
from the open end while shooting WD40 along the blade as you slide it in. Just be careful
as you slide it in to keep it close to the bar so as to not run it through the grip. Once
you get close to the outer end of the grip with the screwdriver stop, grab the grip with
both hands and twist hard. It should break loose. Before re-installing on new bars use
a round wire brush and lacquer thinner to get the old adhesive out.
My bike has 16" bars with a 4.5" riser. I went with the 18" wire kit and everything worked out great.
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