How to Change Motorcycle Handlebars

Save

As most steering is done with the handlebars, they are one of the most important components of a motorcycle. A motorcycle owner might want to replace a motorcycle's original handlebars for reasons of performance, style or to repair handlebars ruined in a crash. This tutorial deals with how to replace two different styles of handlebars: clip-on bars and wide, tubular bars.

Things You'll Need

  • Motorcycle
  • Handlebars
  • Hand grips
  • Allen wrenches
  • Sockets (standard or metric, depending on the make of your bike)
  • 36mm socket (for metric bikes)
  • Socket wrench
  • Grip glue
  • Phillips-head screwdriver
  • 5 mm drill bit
  • Electric drill

Installing Tubular Handlebars

  • Remove the bar end weights and mirrors from the handlebars.

  • Remove the left control housing from the handlebars by removing the screws on the bottom of the housing and gently lifting them from the bar. Take note of the screw placement, as one may be longer than the other.

  • Remove the clutch lever perch and brake master cylinder.

  • Unscrew the throttle assembly and slide it off the handlebars. If the throttle assembly will not slide off the end, you may need to remove one of the throttle cables.

  • Remove the screws from the handlebar mount, noting their placement on the bike so they can be replaced in the proper orientation. Remove the handlebars.

  • Mount and lightly secure the new handlebars, replacing the bar mounts in the same orientation as on the original handlebars.

  • Get on the bike and test the placement of the handlebars. Adjust the angle if necessary.

  • Loosely mount the controls in their appropriate positions and test for tank clearance, turning the handlebars from full lock left to right. Adjust the angle of the handlebars if they touch the fuel tank.

  • Tighten down the handlebar mounts and adjust control housing and throttle assembly to your comfort. Mark the position of the locating pins on the handlebars. These pins are found on the inner section of the switch and throttle assemblies.

  • Using a 5 mm drill bit, drill a hole into the handlebars for each locating pin. This will prevent your switches and throttle from moving out of place.

  • Reinstall the clutch perch, brake master cylinder, throttle assembly and switch assembly.

  • Apply a thin layer of grip glue to the handlebars and slide the new hand grips into place.

  • Reinstall bar end weights and mirrors.

  • Check all bolts and screws, tightening any loose fasteners.

Installing Clip-on Handlebars

  • Remove the bar end weights from the handlebars.

  • Remove the left control housing from the handlebars by removing the screws on the bottom of the housing and gently lifting them off the bar. Pay attention to screw placement, as the screws might be different sizes.

  • Remove the clutch lever perch and brake master cylinder.

  • Unscrew the throttle assembly and slide it from the handlebars. If the throttle assembly will not slide off the end, try removing one of the throttle cables.

  • Using a 36 mm socket, remove the steering stem nut and lock washer.

  • Loosen the upper triple clamp pinch bolts and gently remove the upper triple clamp.

  • Loosen the handlebar pinch bolts and slide the handlebars off the upper fork tube.

  • Slide the new handlebars onto the upper fork tube and loosely tighten the pinch bolts.

  • Get on the bike and test the placement of the handlebars. Adjust the angle as necessary.

  • Loosely tighten the handlebar pinch bolts.

  • Reinstall the upper triple clamp and loosely tighten the upper triple pinch bolts, steering stem nut and lock washer.

  • Loosely mount the controls in their appropriate positions and make sure they don't touch the fuel tank. Turn the handlebars from full lock left to right and adjust if the handlebars touch the fuel tank.

  • Tighten the handlebar pinch bolts, upper triple pinch bolts, steering stem nut and lock washer.

  • Adjust the control and throttle assemblies to your comfort and mark the position of the locating pins on the handlebars. These pins are found on the inner section of the switch and throttle assemblies.

  • Using a 5 mm drill bit, drill a hole into the handlebars for each locating pin to prevent your switches and throttle from moving out of place.

  • Reinstall the clutch perch, brake master cylinder, throttle assembly and switch assembly.

  • Apply a thin layer of grip glue to the handlebars and slide the new hand grips into place.

  • Reinstall bar end weights and mirrors.

  • Check all bolts and screws, tightening any loose fasteners.

Tips & Warnings

  • Be sure that the new handlebars will fit before beginning this process. Clip-on bars are made to fit specific fork diameters. Don't rush this job or you will create more problems.
  • Thread damage can occur by overtightening a bolt. Use a torque wrench, if possible. If you doubt your ability to complete the installation, have the work done by a qualified technician.

References

  • 101 Sportbike Performance Projects; Brasfield, Evans; Motorbooks Workshop; 2004
  • The Professional Motorcycle Repair Program; Professional Career Development Institute; 1995
  • Photo Credit Joe Cereghino
Promoted By Zergnet

Comments

Resources

You May Also Like

Related Searches

Check It Out

How To Travel For Free With Reward Points

M
Is DIY in your DNA? Become part of our maker community.
Submit Your Work!