Step-by-Step Guide to Safely Install Motorcycle Handlebars- A Comprehensive DIY Manual

How to Install Motorcycle Handlebars

Installing motorcycle handlebars can be a daunting task for beginners, but with the right tools and guidance, it can be a straightforward process. Whether you’re looking to upgrade your handlebars for better handling or comfort, or you’re building a custom motorcycle, this article will walk you through the steps to install motorcycle handlebars like a pro.

Before You Begin

Before you start the installation process, it’s important to gather all the necessary tools and materials. Here’s a list of items you’ll need:

1. New handlebars
2. Handlebar clamps
3. Wrenches (both socket and box wrenches)
4. Screwdriver (flat-head and Phillips-head)
5. Locking pliers
6. Thread locker
7. Grease
8. Safety goggles and gloves

Ensure that you have a clean, well-lit workspace and that you’re wearing the appropriate safety gear, such as gloves and safety goggles, to prevent accidents.

Step 1: Removing the Old Handlebars

1. Start by locating the nuts or bolts that secure the handlebars to the motorcycle’s steering column. These are typically located at the top of the steering column and can be accessed by removing the fairing or cover.
2. Once you’ve located the nuts or bolts, use the appropriate wrench to loosen them. If the nuts are tight, you may need to use locking pliers or a socket wrench with a breaker bar.
3. Once the nuts or bolts are loose, gently pull the old handlebars away from the motorcycle, ensuring that you don’t damage any wires or connectors.

Step 2: Installing the New Handlebars

1. Apply grease to the threads of the new handlebar clamps to ensure a smooth fit.
2. Place the new handlebars in the correct position on the steering column, aligning them with the mounting points.
3. Thread the handlebar clamps onto the steering column, making sure that they are tight enough to secure the handlebars but not so tight that they damage the threads.
4. Use the appropriate wrench to tighten the nuts or bolts, ensuring that the handlebars are securely mounted.

Step 3: Connecting the Controls

1. Connect the throttle, brake, and clutch cables to the new handlebars. Ensure that the cables are properly routed and that there is enough slack for full movement.
2. Adjust the cables as necessary to ensure smooth operation. You may need to adjust the cable tension or replace the cables if they are worn or damaged.
3. Test the controls to make sure they are functioning correctly.

Step 4: Final Checks and Adjustments

1. After installing the new handlebars, perform a thorough inspection to ensure that all components are properly mounted and that there are no loose nuts or bolts.
2. Adjust the handlebars to the desired height and angle, ensuring that they are comfortable for you to ride.
3. Check the clearance between the handlebars and any other components, such as the fairing or exhaust, to ensure that there is no risk of contact while riding.

Conclusion

Installing motorcycle handlebars may seem like a challenging task, but with the right tools and a bit of patience, you can do it yourself. By following these steps and taking your time, you’ll have your new handlebars installed and ready to hit the road in no time. Always prioritize safety and consult a professional if you’re unsure about any step of the process. Happy riding!