Now sit in the saddle and rotate the new handlebars until the feel comfortable for the height of the bars. Don’t forget to make any slight adjustments for thicker grips and gloves that may be utilized in this step. Once you have found the comfort spot for locating the location of your new handlebars, lightly tighten the clamps down on the risers. Get off the motorcycle and take a 5 minute break. Get back onto the motorcycle and grab the handlebars and see if that is the natural, comfortable position for your new bars. If this handlebar location is not satisfactory, adjust them some more until you are sure. If when the new handlebars are in the proper location, tighten down the riser clamp good and snug. This should make the “impression mark” into the tape. In addition, try to mark the location of the nub on the underneath side of the handlebars on the tape with a Sharpie pen. Ensure the grips will have sufficient room to clear the top of the fuel tank with the handlebars turned to the sides.
Remove the handlebars from the claps in the top of the risers and ensure there is an impression of a mark for locating the inner end of the nubs on both risers. From the inside end of the nub lay out a slotted hole that will be approximately 7/8” long and 7/16” to ½” wide on the scotch tape. This layout and marking is to drill new holes in the riser clamp portion of the handlebars for the new bars to fit the nubs and for the holes to install the wire bundles through the new handlebars and into the risers.
DRILLING HOLES IN THE NEW HANDLEBARS
Once the centers of the two holes are located from your layout, use a center-punch and mark those locations of the holes through the scotch tape. Remember you are marking a total of 4 holes to be drilled. Use caution when center-punching these holes and only hit the punch enough to give you a good depression. If you use a little more aggressive stroke to the center-punch you risk making the handlebars out of round and then they will not fit down into the risers properly. Don’t ask me how I know this, just be sure and heed the warning.
Use a sharp drill and begin drilling with a small pilot hole. Now increase drill bit sized as needed to finish drilling out the four holes to 7/16” or ½”. One all four holes have been drilled I used a dremel tool with a cut-off blade and cut the remaining material out between the two each drilled holes to make a longer slotted hole. I then used a dremel tool with a grinding wheel to grind off all the sharp edges around the slotted holes to be able to safely pull the cable bundles back through these holes without worry of cutting the cables.
Now the left and right hand bar ends will also require new holed to be drilled so the cable bundles can exit the new handlebars and get to the switch housings. The new bars I received had a small hole existing near the grip ends of the new handlebars. This small hole is there to mate up with the prong that protrudes out of the switch housings and keeps this part of the housing from rotating. I took measurements from the old buckhorn bars for the placement and size of the new holes to be drilled for the switch housings. The holes appeared to be approximately 1/8” from the existing smaller hole in the bars, and were a slotted hole approximately 7/16” by 1” log, with the top of the slotted hole even with the top of the small hole.
I used painters tape again and laid these holes out on the handlebars, then used a center-punch lightly to mark these holes. I drilled them by starting with a pilot hole and progressing up to the 7/16” drill bit for these four holes. I again used the dremel tool with the cut-off blade and removed the remaining material between each of the two drilled holes to make the long slotted holes. A grinding wheel in the dremel was used to remove any sharp ends and to smooth out the sides of both holes so the cable bundles would not be damaged.
Test fit the new handlebars to ensure they will fit down into the risers and over the existing nubs on the risers properly. Rework as required to ensure the new handlebars fit the risers before proceeding further.
PULLING THE CABLE BUNDLES INTO THE NEW HANDLEBARS
We tied a small nut onto a string and lowered the nut into the drilled slotted hole at the right hand switch end of the new handlebars. Using a magnet we were able to get the nut and string out of the slotted hole for the right hand riser. We attached the other end of the string to the cable bundle that goes to the kill switch housing. Using two people, gently keep a light tension on the pull string while the other person pushes and twists the cable bundle until the cable bundle is completely pulled through the right hand side of the new handlebars.
Perform this activity to pull the left hand side cable bundle through the left hand side of the new handlebars.
INSTALLING THE NEW HANDLEBARS
Lower the new handlebars while feeding the cable bundles down through the existing holes in the existing risers until the new handlebars and resting on the risers. Install a riser cap temporarily to support the handlebars.
Take each cable bundle exiting the bottom of each riser and insert them through the opening into the backside of the headlight bucket.
Remove any materials that you used to maintain the individual wires in a bundle earlier.
RECONNECTING THE ELECTRICAL WIRES
Reconnect the electrical wires by using the matching numbers on the Avery labels and second checking them by the wire colors. Double check each connection for tightness and for correct numbers on your labeling or the color of the wires.
Tuck the wire bundles back into the headlight bucket and secure them with the wire keepers to provide enough room for the headlight.
Install the headlight into the headlight bucket using the two Phillips headed screws to secure the headlight retainer ring.
Install the rectangular cover onto the backside of the headlight bucket using the four each screws.
FINAL INSTALLATION OF THE HANDLEBARS, SWITCHES, LEVERS AND GRIPS
Install both handlebar riser clamps and tighten the four each allen headed cap screws tightly. Consider using blue colored lok-tite on these screws.
Install the right hand grip with the throttle sleeve along with the switch housing. Remember to install the nub on the switch housing into the small hole provided in the new handlebars. Install the stub on the end of the throttle cable into the top hole in the throttle sleeve, then install the front cover of the switch housing and tighten the two Phillips headed screws to secure this switch housing.
Install the left hand switch housing by aligning the nub in the switch housing in the existing hole in the new handlebars. Tighten the front portion of the switch housing to the larger half by using the two Phillips head screws.
Install the hand brake lever on the right hand side of the new handlebars and the hand clutch lever on to left hand side of the new handlebars. Use the back side of the hand lever clamps and the cap headed screws and install these in a loose condition.
Use sandpaper or other means to roughen up the left hand portion of the new handlebars for the installation of the left hand grip. Use your preference of adhesive and install the left hand sided grip.
Sit back in the saddle and adjust the mirrors by loosening the lever clamp hex head cap screws and reposition them, as well as the mirror stem nuts so the mirrors can be adjusted to work with their new positioning on the new handlebars. Tighten both the mirror stem nuts and the hand lever cap screws when the mirrors have been properly adjusted.
Reinstall the windshield if one was previously installed on your motorcycle.
Reinstall any other mounts and gadgets onto the new handlebars.
Re-connect the positive battery cable to the battery.
POST NEW HANDLEBAR INSTALLATION ELECTRICAL CHECK
Shift motorcycle into neutral and turn the key on.
Check to make sure headlight is illuminated.
Check to make sure indicator lights are working properly.
Start the motorcycle and allow it to run for a while. Then turn off the motorcycle using the red kill switch to make sure that switch is functioning properly.
Restart the motorcycle.
Check the right hand and left hand turn signal lights in the front and the back of the motorcycle.
Check the high beam and low beam of the headlight to make sure it is working.
Check the hand lever brake to see if the brake light on the rear illuminates.
Turn the motorcycle off by using shifting into gear and lower the kickstand.