Changing Handlebars?
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6th Gear
Joined: Nov 2004
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Changing Handlebars?
Just wondering if anyguys changed out your handle bars. If so, is it something anybody can do or should I get my mech. to do it. I am taking all the grips, cables, and levers off the old set and transfering it all over to the new bars? Any problems or tips you guys could share with me would help.
Thanks Scooter
Thanks Scooter
Banned
Joined: Jul 2005
Posts: 14,082
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RE: Changing Handlebars?
I agree with John, as long as the cable lengths are good it is pretty straight forward, on most bikes you only have a couple of inches to spare for a bar change, on the throttle cables. Be careful when you tighten down the clamp on the throttle side. If you are not very careful you will have the cable in a bind and it will not return to idle position. It is a simple matter to tighten down the bolts eqaually and have the clamp positioned correctly. Try the throttle before starting the bike, it should return freely or you need to readjust.
Cruiser
Joined: Nov 2005
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RE: Changing Handlebars?
Cover your tank with a towel or something. It's real easy to drop the bars on it. The hardest part is probably removing the left grip. I stuck a screw driver between the grip and bar and sprayed electric cleaner in then twisted the grip to break up the glue. I went from the stock 28" bars on my XL883 to 31" bars with the same rise off a 1200R. I had to unbolt the clamp that holds the front brake line to the top triple tree. It's still loose so I need a longer line or straighten the metal part of the line to gain some length and re-attach it.
Road Warrior
Joined: Oct 2005
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RE: Changing Handlebars?
The mechanics of the change have been pretty well covered. My suggestion is to ask a H-D serviceman if your stock control cables are long enough to work with the new bars. I have found that it works for me to break loose the two grips, then loosen the clamp at the fork head and slide the bar to the left to allow enough slack to remove the throttle grip. With that grip off, just slide the bar to the right and remove it from the clutch side. That way you don't have to totally remove the fasteners on anything. Reassembly is the opposite motion. I second MuddyXL's suggestion about covering your tank. I would only add that it is a good idea to actually tape down that towel to prevent it from falling off at an inopportune moment. ......... BC
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