Sportster Models 883, 883 Custom, 1200 Custom, 883L, 1200L, 1200S, 1200 Roadster, XR1200, and the Nightster.
Sponsored by:
Sponsored by:

My new clean handlebars ....

Thread Tools
 
Search this Thread
 
Old Oct 18, 2011 | 10:40 AM
  #1  
joebotics's Avatar
joebotics
Thread Starter
|
Road Warrior
15 Year Member
Photogenic
Photoriffic
Joined: Mar 2009
Posts: 1,408
Likes: 56
From: Vallejo, California
Default My new clean handlebars ....

I want my Sporty to look as barebones as possible, I was always annoyed by the way the handlebars looked with the bulky master brake cylinder, throttle / brake, electrical cables... but being a poor, cheap bastard as I am... I cannot afford an Exile integrated brake system or similar offers.. I started thinking about cheap ways to relocate/ hide things... throttle system was easy... I used an internal throttle kit from Demons Cycle... I relocated start/ignition switches around the bike (I still need to work on some small / simple looking switches for the horn / kill switch).. the biggest issue of course was the master brake cylinder, so I made a bracket to relocate the master brake cylinder on top of the front brake caliper and then used a short brake line to rejoin the brake components .... here:


Name:  WP_000037.jpg
Views: 2179
Size:  140.3 KB


I then attached the master cylinder's lever to a cheap bicycle lever using a generic ATV clutch cable that I ran internally (the bicycle lever is the bar end reversed type designed to run the cable internally for cleaner looks).. here is a pic:


Name:  WP_000034.jpg
Views: 3755
Size:  118.7 KB


I used cheap bicycle foam grips... they are durable and they absorb a lot of the vibration.... I wanted the handlebars to look like the "chubby" 1 1/2 inch for a more streamlined appearance... but heck... besides costing a fortune... they do not fit in a inverted handlebar configuration like mine... gotta be cheap... so I covered them with a vinyl hose that I got at home depot:


Name:  WP_000017.jpg
Views: 1822
Size:  52.0 KB


After an awful painting job, I installed cheap bar end mirrors from Cycle Gear.. they are pretty decent during the day. not that great at night.. but still usable...

here is how the handlebars look now:


Name:  WP_000038.jpg
Views: 1940
Size:  121.4 KB

Name:  WP_000036.jpg
Views: 3139
Size:  148.2 KB



Riding position with this handlebar setup:


Name:  WP_000094.jpg
Views: 2799
Size:  202.8 KB

Name:  WP_000092.jpg
Views: 2943
Size:  158.5 KB


The relocated master cylinder works surprisingly well, I already rode the scooter for about 7k miles with no issues so far (including riding in the fun although more demanding twisty mountain roads around Sturgis)...

So, what do you think fellas?... good idea?... stupid to the point I should be banned from the forums ?? :-)

BTW... I just found out about a kit that allows you to do what I did:

http://www.fabkevin.com/Remote%20Master.htm

Happy riding!!
.
.
.
 
Reply
Old Oct 18, 2011 | 10:44 AM
  #2  
emperor wurm's Avatar
emperor wurm
Road Warrior
15 Year Member
Liked
Loved
Community Favorite
Joined: Apr 2010
Posts: 1,805
Likes: 97
From: Corona, Ca
Default

whoa dude, what size tire are you running on the front? that tire runs with the stock forks with no problem? what year is your bike? looks gnarly, I like it
 
Reply
Old Oct 18, 2011 | 10:48 AM
  #3  
Gpsjr10's Avatar
Gpsjr10
Outstanding HDF Member
Joined: Jun 2007
Posts: 2,541
Likes: 11
From: Elyria, OH
Default

That is some serious redneck engineering... I love it when people use things on their bike that were made for something else and make it work. Good job!
 
Reply
Old Oct 18, 2011 | 10:51 AM
  #4  
joebotics's Avatar
joebotics
Thread Starter
|
Road Warrior
15 Year Member
Photogenic
Photoriffic
Joined: Mar 2009
Posts: 1,408
Likes: 56
From: Vallejo, California
Default

Originally Posted by emperor wurm
whoa dude, what size tire are you running on the front? that tire runs with the stock forks with no problem? what year is your bike? looks gnarly, I like it
hey!... I bought an old FL complete wide glide front end + rear rim at a flea market.. the front tire is a "Rear" AM42 Avon Venom X MT90H-16 (I know... a rear tire installed in the front.. blasphemous!!!, this tire is very grippy and handles great !!!)... rear tire is a "Rear" AM42 Avon Venom X 150/80VB-16
.
.
.
 
Reply
Old Oct 18, 2011 | 11:00 AM
  #5  
scooter1128's Avatar
scooter1128
Road Captain
Veteran: Marine Corps
15 Year Member
Liked
Community Favorite
Joined: May 2009
Posts: 717
Likes: 18
From: perry, fl
Default

whats the gas mask for? very creative with the bike!!
 
Reply
Old Oct 18, 2011 | 11:12 AM
  #6  
HERE's Avatar
HERE
Road Warrior
Joined: Sep 2010
Posts: 1,785
Likes: 5
From: Louisiana
Default

I'm digging those inverted levers. Sweet idea.
 
Reply
Old Oct 18, 2011 | 11:12 AM
  #7  
Ragnar Danneskjöld's Avatar
Ragnar Danneskjöld
Road Warrior
Joined: Mar 2010
Posts: 1,948
Likes: 4
From: Ottawa, Ontario
Default

Looks badass. I love the creativity. Where did you put the controls (signals, hi/low, etc)?

Also, you had a write up, if I remember correctly, on how you mounted and wired your rear signals?
 

Last edited by Ragnar Danneskjöld; Oct 18, 2011 at 11:15 AM.
Reply
Old Oct 18, 2011 | 11:33 AM
  #8  
doobs48's Avatar
doobs48
Tourer
Joined: Aug 2011
Posts: 315
Likes: 0
From: MN
Default

Looks awesome! Love seeing different things that people do to their bikes.
 
Reply
HD Forum Stories

The Best of Harley-Davidson for Lifelong Riders

story-0

7 Times Harley-Davidson Chucked Tradition Out the Window

 Verdad Gallardo
story-1

7 Surprising Harley-Davidson Products that Are Not Motorcycles

 Verdad Gallardo
story-2

8 Best Harley-Davidson Motorcycles Ever

 Pouria Savadkouei
story-3

10 Worst Harley-Davidson Motorcycles Ever

 Pouria Savadkouei
story-4

Killer Custom's Jail Break Is The Breakout That Refused to Blend In

 Verdad Gallardo
story-5

Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?

 Verdad Gallardo
story-6

Harley-Davidson Reveals Super Cool Cafe Racer Concept

 Verdad Gallardo
story-7

Engraved Rebellion: Inside Bundnerbike's Glam Rock II

 Verdad Gallardo
story-8

10 Motorcycles You Should Never Buy

 Joe Kucinski
story-9

10 Things Harley-Davidson Needs to Fix in 2026

 Verdad Gallardo
Old Oct 18, 2011 | 11:35 AM
  #9  
poisonthesteve's Avatar
poisonthesteve
Tourer
Joined: May 2011
Posts: 333
Likes: 0
From: Orange County, New York
Default

that bike is badass man. i love it. please tell me you wear that mask while riding.
 
Reply
Old Oct 18, 2011 | 11:41 AM
  #10  
joebotics's Avatar
joebotics
Thread Starter
|
Road Warrior
15 Year Member
Photogenic
Photoriffic
Joined: Mar 2009
Posts: 1,408
Likes: 56
From: Vallejo, California
Default

Originally Posted by scooter1128
whats the gas mask for? very creative with the bike!!
I have no windshield and ride with a half or 3/4 helmets... some areas in Florida are notorious for big bugs hitting you in the face while riding on the highway.. my doomsday face-mask helps a lot in those occasions ...
.
.
.
 
Reply



All times are GMT -5. The time now is 03:59 PM.

story-0
7 Times Harley-Davidson Chucked Tradition Out the Window

Slideshow: Harley-Davidson built its reputation on nostalgia, but every so often, the company took a hard left turn into the future.

By Verdad Gallardo | 2026-05-20 11:18:19


VIEW MORE
story-1
7 Surprising Harley-Davidson Products that Are Not Motorcycles

Slideshow: The bar-and-shield logo shows up on far more than motorcycles, some of the company's most unexpected products have nothing to do with riding.

By Verdad Gallardo | 2026-04-29 16:50:35


VIEW MORE
story-2
8 Best Harley-Davidson Motorcycles Ever

Slideshow: Not every Harley gets it right, but these are the ones that genuinely earned their reputation.

By Pouria Savadkouei | 2026-04-15 14:23:21


VIEW MORE
story-3
10 Worst Harley-Davidson Motorcycles Ever

Slideshow: From the troubled AMF years to modern misfires, these bikes earned reputations for reliability issues, questionable engineering, or disappointing performance.

By Pouria Savadkouei | 2026-04-01 20:01:09


VIEW MORE
story-4
Killer Custom's Jail Break Is The Breakout That Refused to Blend In

Slideshow: Killer Custom's "Jail Breaker" build focuses more on stance and visual aggression than mechanical overhaul.

By Verdad Gallardo | 2026-03-18 19:20:32


VIEW MORE
story-5
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?

Slideshow: The Swiss custom shop has taken a Harley Softail and stretched it into something so long and low that it looks closer to a rolling sculpture than a conventional motorcycle.

By Verdad Gallardo | 2026-03-07 16:15:30


VIEW MORE
story-6
Harley-Davidson Reveals Super Cool Cafe Racer Concept

Slideshow: Harley-Davidson's new RMCR concept revives the café racer formula with modern hardware-and it may be exactly the reset the company needs.

By Verdad Gallardo | 2026-03-04 12:23:37


VIEW MORE
story-7
Engraved Rebellion: Inside Bundnerbike's Glam Rock II

Slideshow: A standard cruiser becomes an intricate metal canvas in the hands of a Swiss custom house known for pushing Harley-Davidson platforms far beyond their factory brief.

By Verdad Gallardo | 2026-02-24 18:19:44


VIEW MORE
story-8
10 Motorcycles You Should Never Buy

Slideshow: There is no shortage of great motorcycles to buy, but we would avoid these ten.

By Joe Kucinski | 2026-02-19 14:50:51


VIEW MORE
story-9
10 Things Harley-Davidson Needs to Fix in 2026

Slideshow: Harley-Davidson's challenges aren't abstract; they show up in dropping shipments, shrinking dealer traffic, and strategic decisions that aren't yet translating into growth.

By Verdad Gallardo | 2026-01-13 18:33:17


VIEW MORE