How To Install Handlebars On Motorcycle

How to Upgrade Motorbike Handlebars

Updated: Jun. 30, 2022

Make that onetime clunker stylish over again

FH11JUN_HANBIK_01-2 Family Handyman

If yous're tired of the dated look of your motorbike, consider swapping out the handlebars for a newer expect. It's an easy upgrade, and you'll salve hundreds of dollars when y'all do information technology yourself.

Replacement procedure

Photo 1: Measure out earlier yous buy

Pick any spot along the handlebar to measure its diameter. Then buy the correct bar for your bike.

Photo 2: Disconnect wires, and then label

Find the wires from the handlebar harness and disconnect them one at a time. Use masking tape to each connector and mark them for reassembly. Don't disconnect any other wires.

Photo three: Blow and twist the grip off

Insert a compressed air gun into the grip and clasp the trigger. That'll inflate the grip enough so y'all can twist information technology and break the adhesive.

Photo 4: Make room for the harness

Grind out a section of the command mounting subclass with a high-speed rotary tool and a cutting or grinding wheel. So shine the edges so it won't cut into the harness.

Photo 5: Fill and bleed

Add together fresh brake fluid. Then follow the brake bleeding process for your wheel.

If you're still riding around with those "ape hanger" handlebars from the '70s, face it, you're no longer cool. I'll show you how to alter out your handlebars yourself and save about $200.

I chose a '70s-vintage Honda because it was one of the more popular bikes back then. On this bike, the wiring harness runs through the centre of the handlebars. The new bar won't have holes for the harness. So yous've got 2 options. You can either drill out the new bar or modify the bracket for the controls and run the harness forth the outside of the bar.

Start the project by measuring the diameter of your handlebars (Photo 1). Pick the bar style you similar, but check with either the bar manufacturer or your dealer to make sure the new bar provides enough turning clearance to avoid hitting the gas tank.

Y'all'll also demand shorter restriction, clutch and throttle cables and a shorter restriction line. Your local dealer can send your old cables out for professional modification, or yous can buy new cables (almost twice the toll).

Remove the headlight to access the harness splice area. Then disconnect the wires from the handlebar harness (Photo 2). Next, drain the restriction fluid reservoir and disconnect and remove the restriction line, switches, levers and throttle. Then remove the left paw grip (Photo 3). Unbolt the handlebar and motility information technology to the workbench.

Remove the harness from the bar by pulling and feeding at the same fourth dimension. If the harness binds, eject in a generous dollop of wire-pulling lube (available in the electric department at dwelling house centers). Once it's out of the sometime bar, make clean off the lubricant and rewrap the harness with new electrical tape.

To run the harness on the outside of the new bar, modify the command brackets (Photo iv). Reconnect the wiring harness, controls and levers, and install the shorter cables and restriction hose. Secure the wiring harness with zip ties. Then top off the brake fluid reservoir (Photo five). Test all the electrical connections and the brake performance before you take information technology out for a spin.