How to Remove and Install Motorcycle Handlebars

  1. Before you remove the existing handlebars, estimate where your hands feel most comfortable by holding them higher, lower, or wider than your existing bars. If the width and hand position of your current bars is comfortable, and handlebar height is your only concern, you might want to consider raising or lowering them with custom risers. If you deciding to change the bars, measure the difference in height, width, or hand position, add it to the height of your existing bars, and refer to your measurements when buying new bars. When deciding on width, always remember to check the fuel tank clearance. Wider bars might dent your tank if you turn to hard to the left or right.
  2. Remove the brake lever/master cylinder unit, switch housing, throttle control, and any other accessories from the right side of the handlebars, taking notice and care to remove all zip ties or clamps that may be securing the wiring harness and restraints attached to the throttle and idle cables. When finished backing out throttle and idle cable adjusters, and removing the throttle control, remove the brass ferrules from the ends of the cables and put them somewhere safe and out of the reach of children. They are extremely easy to lose, and exceptional hard to find. Remove the hand grip, clutch lever assembly, switch housing, and any other accessories from the left bar. Also Remove all wiring harness ties and clamps and any restraints attached to the clutch cable. Note to self to place all components on clean rags or towels so they do not scratch any painted parts, or else you will be mad at yourself.
  3. Left hand grips are most likely glued on, and may require some force and effort to remove. Some people prefer to simply slit the hand grip with a razor knife and replace it. Others replace it by freeing the grip by prying up its outer end with a long, thin screwdriver and either spraying compressed air between the grip and bar to break it free, or spraying a glue solvent between the grip and the bar, twisting the grip free after the solvent has begun to dissolve the glue. To remove glue residue use solvent after removal.
  4. Remove the riser cover (if one is installed) and riser clamps. Remove the handlebars. You may want to change the risers if desired.
  5. Install the new handlebars in the reverse order of how you removed the old ones. Center the bars on the risers and install the riser clamps and cover. Swing the installed bars hard left and right, checking one last time for proper fuel tank clearance.
  6. Install the clutch lever assembly/switch housing on the left bar. Make sure that the wires are positioned properly in the recesses of dimpled bars. Coat the end of the bar with supplied glue, and quickly slide on the new hand grip, seating it tightly against the switch housing. Reattach and any other accessories you removed from the left bar. Replace any ties, clamps, or cable restraints that you removed.
  7. Install the brake lever and switch housing and master cylinder on the right bar. Before tightening the switch housing, reinstall the brass ferrules on the cables, seating them back into their slots in the throttle control. Slide the throttle control onto the bar, seating it in its groove in the switch housing. Finish tightening the switch housing. Replace any other accessories that you removed from the right bar. Replace any ties, clamps, or cable restraints that you removed.
  8. Readjust the throttle and idle cables, following the manufacturers recommended procedure. Replace any ties or clamps that you removed.
  9. Make sure to test all switches to make sure you did not damage any wires. Swing the handlebars hard right and left again, making sure the throttle, idle, and clutch cables do not hang up on the bars.
  10. ?Have fun riding and enjoy your new handle bars!!