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Handlebar swap

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5.8K views 9 replies 4 participants last post by  tierod222  
#1 ·
#2 ·
depends on the year of the bike ( cable lengths) The type of bar and if you want to route wires inside the bar.
earlier years '06 and back have more excess cable than later so re routing usually helps along w/ the extra length.
'07 and up have a little shorter cables and may need new longer ones.
That is if your new bar isn't too tall ( apes ).

Other than that you have to get it off the triple tree and take off all the stuff on the bar and mount it on the new.
 
#3 ·
The process is pretty easy. Its just making sure everything fits.
The fork width is around 11", so keep that is mind when selecting bars
The diameter needs to be 1" for the mounts and grips to fit
if you have an 07+ C50, you will need longer cables if you go past 12". 12" need cable re-routing. 10" is fine. If you have an older model, you wont need to re-route cables with 12" apes, but will still need longer cables if you go up more than 12".

Allen wrenches and wd-40 and you will get it done in less than 30 minutes.
 
#7 · (Edited)
First up make sure you cover your tank as anything you drop will land on it. Don't undo the riser clamps yet.

1. Loosen bar end weights and pull them out. (do not undo them all the way as the nut will end up in your bars)
2. Remove left hand grip (slide a screwdriver between the grip and bar and spray wd40)
3. Undo the screws in the right hand switch gear and disconnect the little connector on the front brake.
4. Loosen off the throttle cables by screwing in the adjuster.
5. Slide the entire throttle assembly of the end of the bar.
6. Remove left and right levers and mirror assemblies (you may have to loosen the risers to allow enough travel).
7. Undo riser clamps and remove bars.
8. Make sure the new ones have locating holes for the switch assemblies
9. If not, mark and drill new holes in the replacement bar.
10. Reassemble.

If you're replacing the risers you will have to remove them and refit the new ones. Most aftermarket ones don't have the same diameter bolt so you may have to make shims to take up the slack.