How to Replace a FLHT Handlebar
Harley-Davidson's FLHT Electra Glide is among the manufacturer's classic road bike designs. Although the technology has continued to develop since the first model rolled out in 1996, the handlebar components remain relatively similar. Replacing damaged handlebars or installing a different style is not a complicated job. The average do-it-yourself mechanical with a degree of aptitude and standard tools can replace the handlebars on a FLHT motorcycle.
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Things You'll Need
- Hex wrenches
- Nylon ties
- Torx driver
- Spray lubricant
- Plastic sandwich bag
- Thick rubber bands
- Wire cutters
Instructions
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Left Grip Assembly
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1
Loosen and remove the fixing bolts at the clutch hand-lever clamp with a hex wrench. Save the bolts and the lower portion of the clamp. Secure the clutch cable to the upper stem of the left fork with a nylon tie and allow the lever to hang suspended.
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2
Remove the socket bolts at the left handlebar switch assembly with a torx driver. Separate the upper and lower portions of the switch housing from the handlebars. Set the bolts and housing aside. Secure the wiring to upper fork tube with a nylon tie and allow the switches to hang suspended.
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3
Remove the left handlebar grip. Depending on the type, loosen small fixing bolts and remove the grip, or spray the inside rim of the grip with lubricant and slide it off the bars by hand.
Right Grip Assembly
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4
Loosen and remove the fixing bolts at the brake-lever clamp with a hex wrench. Save the bolts and the lower portion of the clamp. Secure the brake cable to the upper stem of the right fork with a nylon tie and allow the lever to hang suspended.
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5
Remove the socket bolts at the throttle-switch assembly with a torx driver. Slide the assembly off the end of the bars. Secure the throttle cables and wiring to the upper fork tube with a nylon tie and allow the throttle-switch assembly to hang suspended.
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6
Loosen and remove the fixing bolts at the disc brake reservoir clamp with a hex wrench. Hold the reservoir in one hand as you remove the lower portion of the clamp below the bars.
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7
Seal the reservoir in a plastic sandwich bag wrapped with thick rubber bands. Secure the reservoir to the lower portion of the steering head with two nylon ties.
Handlebars
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8
Loosen and remove the socket bolts at the handlebar clamp cover with a hex wrench. Save the cover and bolts. Remove the remaining socket bolts at the right and left handlebar clamps. Lift the handlebars out of the clamp bases at the steering head.
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9
Position the replacement handlebars in the clamp bases. Center the bars each way. Attach the bars with the saved clamps and bolts. Adjust the position of the bars before you tighten the bolts securely with the hex wrench. Reattach the clamp cover and tighten the bolts securely.
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10
Cut the nylon ties holding the disc brake reservoir to the steering head with wire cutters. Remove the rubber bands and the plastic bag. Attach the reservoir to the handlebars with the saved clamp and bolts, making sure the reservoir is level instead of tilted forward or back.
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11
Cut the nylon tie at the throttle-switch assembly wires and cables. Slide the assembly on the end of the right bar by hand, making sure the throttle cables and wires are at the underside of the bars. Fix the assembly to the handlebars with the saved clamp and bolts.
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12
Cut the tie holding the left switch assembly. Attach the assembly to the left bar with the saved clamp and bolts. Repeat this with the clutch lever and secure it to the bars with the saved clamp and bolts. Fit the saved grip onto the end of the left bar.
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1
Tips & Warnings
Remove any mirrors or other accessories before removing the old handlebars. Reattach each in the reverse order as removed.
Save time and avoid confusion by placing all bolts and clamps in a utility pan as you go.
References
- Photo Credit Jupiterimages/Photos.com/Getty Images
