Sep 29, 2024

Handle with Care: How to Change Handlebars on Your Harley

Why Change Handlebars on a Harley?

Changing the handlebars on your Harley-Davidson motorcycle is a popular modification that can significantly impact your riding experience. The stock handlebars that come with your bike may not always provide the desired level of comfort or style, leading many riders to explore aftermarket options.

Here are some of the main reasons why you might consider swapping out your handlebars:

Improved Comfort and Ergonomics

One of the primary motivations for changing handlebars is to achieve a more comfortable and ergonomic riding position. The stock handlebars may cause discomfort or strain on your back, shoulders, or wrists, especially during long rides.

By choosing handlebars with a different rise, sweep, or width, you can adjust your riding posture to better suit your body type and preferences, reducing fatigue and increasing overall comfort.

Customization and Personal Style

Harley-Davidson motorcycles are renowned for their customization potential, and handlebars play a significant role in defining the overall look and feel of your bike. Changing the handlebars allows you to personalize your ride and make it truly your own.

Whether you prefer a sleek, low-profile look or a more aggressive, high-rise stance, the right handlebars can transform the appearance of your Harley and reflect your personal style.

Performance and Control

While comfort is a primary concern, handlebars can also influence your bike's performance and handling characteristics. Different handlebar styles can alter the leverage and control you have over your motorcycle, potentially improving maneuverability, stability, and overall riding dynamics.

For example, taller handlebars may provide better leverage for navigating tight turns or negotiating challenging terrain.

Types of Handlebar Styles for Harleys

There are several popular handlebar styles available for Harley-Davidson motorcycles, each offering a unique riding experience and aesthetic appeal. Here are some of the most common options:

Ape Hangers: Ape hangers are tall, high-rising handlebars that extend well above the rider's shoulders. They provide a relaxed, stretched-out riding position and a distinct, aggressive look. Ape hangers are popular among cruiser enthusiasts and are often seen on custom Harleys.

Beach Bars: Beach bars, also known as mini-apes, are slightly shorter than ape hangers but still rise above the rider's shoulders. They offer a comfortable, upright riding position and a classic, laid-back style. Beach bars are a popular choice for riders seeking a balance between comfort and style.

Drag Bars: Drag bars are low-profile handlebars that position the rider's arms closer to the body, creating a more aggressive, forward-leaning riding stance. These handlebars are often associated with performance and speed, making them a favorite among sportbike enthusiasts and drag racers.

Z-Bars: Z-bars, also known as buckhorn bars, feature a distinctive Z-shaped bend that positions the grips closer to the rider. This design provides a comfortable, upright riding position and a unique, vintage-inspired look that complements the classic styling of many Harley models.

Touring Bars: Touring bars are designed with long, swept-back extensions that position the grips further away from the rider, promoting a relaxed riding posture ideal for long-distance cruising. These handlebars are commonly found on Harley-Davidson touring models and are favored by riders who prioritize comfort on extended trips.

Each handlebar style offers its own unique combination of ergonomics, control, and aesthetic appeal. When choosing new handlebars for your Harley, consider your riding preferences, comfort needs, and the desired look you want to achieve.

Choosing the Right Handlebars

When it comes to changing the handlebars on your Harley, selecting the right ones is crucial for ensuring a comfortable and enjoyable riding experience.

Several factors should be considered to ensure the new handlebars complement your riding style, body type, and overall bike geometry.

First and foremost, consider your riding posture. Different handlebar styles can significantly impact your body position on the bike.

For instance, taller ape hangers will keep your arms raised higher, while lower-profile bars will have you leaning forward more.

Evaluate your preferred riding stance and choose handlebars that will allow you to maintain a comfortable and relaxed position for extended periods.

Another essential factor is arm reach. Handlebars that are too wide or too narrow can cause strain on your shoulders, back, and arms, leading to discomfort and fatigue during long rides.

Measure the distance between your shoulders and choose handlebars that align with your arm length and range of motion.

Additionally, consider the overall geometry of your Harley. The handlebar style should complement the bike's rake angle, trail, and wheelbase to maintain optimal handling and stability.

Consult with experienced mechanics or refer to manufacturer guidelines to ensure the new handlebars won't adversely affect your bike's performance.

Finally, think about your personal style and preferences. Handlebars come in various shapes, sizes, and finishes, allowing you to customize the look and feel of your Harley to match your unique personality and taste.

Tools and Supplies Needed

To replace the handlebars on your Harley-Davidson motorcycle, you'll need the following tools and supplies:

Basic tool kit (combination wrenches, sockets, ratchet, Allen wrenches)
Torque wrench
Wire cutters/crimpers
Electrical tape
Cable lubricant
Threadlocker (medium strength)
Shop rags
New handlebars (make sure they're compatible with your bike model)
Handlebar clamps or risers (if needed)
Grip glue or adhesive
New handlebar grips
Throttle cables and clutch cables (if required for your new handlebar setup)

It's essential to have all the necessary tools and supplies on hand before starting the project. This will ensure a smooth and efficient handlebar replacement process. Additionally, having the right tools will help prevent any damage to your motorcycle or potential injuries during the installation.

Step-by-Step Handlebar Replacement Guide

Changing the handlebars on your Harley-Davidson motorcycle is a rewarding project that can transform the look and feel of your ride. Follow these detailed steps to ensure a successful handlebar replacement:

Prepare the Motorcycle: Begin by securing your Harley on a level surface and engaging the parking brake. Remove any accessories or components that may interfere with the handlebar removal, such as mirrors, control housings, or electrical components.
Remove the Old Handlebars: Locate the handlebar clamps or risers that secure the handlebars to the fork tubes. Typically, you'll need to loosen and remove the clamp bolts or riser nuts to free the handlebars. Take care not to damage any wiring or brake lines during this process.
Disconnect Cables and Wires: Carefully disconnect any cables, wires, or hoses attached to the handlebars or control housings. Make note of their routing and connections for easier reassembly later.
Install the New Handlebars: Clean the fork tube mounting surfaces and apply a small amount of threadlocker or anti-seize compound to the new handlebar clamps or risers. Position the new handlebars according to the manufacturer's instructions and tighten the clamps or risers to the specified torque settings.
Reconnect Cables and Wires: Carefully route and reconnect all cables, wires, and hoses to their respective locations on the new handlebars and control housings. Double-check that everything is properly secured and functioning correctly.
Adjust and Tune: Adjust the handlebar position, throttle and brake lever angles, and any other components as needed for optimal comfort and control. Ensure that all cables and wires have sufficient slack and are not binding or rubbing against any surfaces.
Final Checks and Test Ride: Once everything is reassembled and adjusted, perform a thorough safety inspection. Check for proper operation of all controls, lights, and systems. Take your Harley for a test ride in a safe area to ensure everything is functioning correctly and to your satisfaction.

Remember, patience and attention to detail are crucial during this process. If you encounter any difficulties or have concerns, consult a professional mechanic or refer to your Harley-Davidson service manual for guidance.

Safety Considerations

Replacing the handlebars on your Harley-Davidson motorcycle is a task that requires caution and attention to safety. It's crucial to follow proper procedures to ensure your safety and the integrity of your bike. Here are some important safety considerations to keep in mind during the handlebar replacement process:

Secure the motorcycle: Before beginning any work, ensure your Harley is properly secured and supported. Use a motorcycle lift or jack stand to elevate the front end, preventing the bike from falling over during the process.
Handle wiring and cables with care: The handlebar area is a hub for various wires and cables, including the throttle cables, clutch cable, and electrical wiring. Take extreme care when disconnecting and reconnecting these components to avoid damage or improper routing.
Wear protective gear: It's always a good idea to wear appropriate protective gear, such as gloves, safety glasses, and closed-toe shoes, when working on your motorcycle. This will help prevent injuries from tools, sharp edges, or accidental drops.
Follow torque specifications: Overtightening or undertightening bolts and fasteners can lead to potential safety issues. Refer to your service manual or the handlebar manufacturer's instructions for proper torque specifications and tighten all components to the recommended values.
Check for clearance: Ensure that the new handlebars provide adequate clearance for your hands, legs, and body when seated in the riding position. Improper clearance can lead to discomfort, control issues, or even injury.
Test before riding: Once the handlebar installation is complete, perform a thorough safety check. Test the throttle, clutch, and brake controls for proper operation and ensure that all wiring and cables are correctly routed and secured.

Adjusting and Tuning After Installation

After successfully installing your new handlebars on your Harley, it's crucial to make the necessary adjustments and tuning to ensure proper functionality and optimal riding experience.

Even slight changes in handlebar positioning can affect various components, making it essential to fine-tune them for safe and comfortable operation.

One of the primary adjustments is cable routing. Depending on the handlebar style and positioning, you may need to reroute the cables for the clutch, throttle, and brake lines.

Ensure that the cables have sufficient slack and aren't kinked or pinched, as this can lead to binding or premature wear. Proper cable routing not only enhances smooth operation but also prevents potential safety hazards.

Another critical adjustment is the positioning of the brake and clutch levers. With the new handlebar setup, you'll want to adjust the levers to a comfortable and accessible position for your hand size and riding style.

This adjustment ensures you can easily reach and operate the levers without straining or compromising control.

Similarly, the throttle grip may require adjustment to align with the new handlebar position.

A misaligned throttle can lead to an uncomfortable or awkward grip, potentially causing fatigue or loss of control during rides. Take the time to adjust the throttle grip to a natural and comfortable position for your hand and wrist.

In some cases, you may need to adjust the angle of the handlebar risers or clamps to achieve the desired handlebar positioning and ergonomics.

This adjustment can affect the overall riding position and should be done carefully to maintain proper weight distribution and balance.

Finally, it's essential to check and adjust the free play in the throttle, clutch, and brake cables after installation. Proper free play ensures smooth operation and prevents binding or excessive wear on these critical components.

Remember, proper adjustments and tuning after handlebar installation are crucial for ensuring a safe, comfortable, and enjoyable riding experience on your Harley. Take the time to make these adjustments carefully, and don't hesitate to consult a professional mechanic or refer to your owner's manual for specific instructions and recommendations.

Handlebar Accessories and Customization

Once you've installed your new handlebars, the customization possibilities are endless. Popular accessories include upgraded grips, handlebar risers, and control relocation kits.

Grips come in a variety of materials like rubber, gel, or billet aluminum to enhance comfort and style. Look for grips with vibration damping and a grip pattern that suits your riding style. Heated grips are also a popular option for cold weather riding.

Handlebar risers raise the handlebar position for a more upright and comfortable riding stance. They come in different rise heights to dial in the perfect ergonomics.

Control relocation kits allow you to reposition the hand controls like the brake, clutch, and throttle to accommodate your new handlebar setup. This ensures proper control positioning and lever engagement.

Other accessories include handlebar end weights or mirrors to add a custom touch. Be sure to consider any additional wiring requirements for things like heated grips or remounting electronics. With the right accessories, you can truly make your new handlebars your own.

Legal Considerations and Regulations

When it comes to modifying your Harley-Davidson motorcycle, it's crucial to be aware of the legal considerations and regulations that may apply. Handlebar modifications, in particular, are subject to specific rules and guidelines to ensure the safety of both the rider and other road users.

In most states, there are height restrictions for handlebars. These regulations are in place to prevent handlebars from being too high, which could compromise the rider's control and visibility.

Typically, handlebars should not extend beyond the rider's shoulder height when seated on the motorcycle. It's essential to check your local laws and regulations to ensure compliance.

Additionally, some states may require specific certifications or approvals for aftermarket handlebars. These certifications ensure that the handlebars meet safety standards and are compatible with your specific Harley model.

Failure to obtain the necessary certifications could result in fines or legal consequences.

It's also important to note that certain handlebar modifications may void your motorcycle's warranty or insurance coverage.

Before making any changes, it's advisable to consult with your Harley-Davidson dealer or insurance provider to understand the potential implications.

Maintenance and Care for New Handlebars

Proper maintenance and care for your new handlebars are crucial to ensure their longevity and optimal performance. Here are some tips and best practices to keep your handlebars in top condition:

Regular Cleaning: Regularly clean your handlebars to remove dirt, grime, and road debris. Use a mild soap and water solution or a dedicated motorcycle cleaner. Avoid harsh chemicals or abrasives that can damage the finish.
Lubrication: Lubricate the handlebar mounting points and any moving parts, such as risers or adjustable components, with a high-quality lubricant designed for motorcycles. This will prevent corrosion, squeaks, and premature wear.
Tightness Checks: Periodically check the tightness of all bolts, clamps, and fasteners securing the handlebars. Vibrations and normal use can cause them to loosen over time, leading to potential safety hazards.
Finish Protection: If your handlebars have a chrome or polished finish, consider using a high-quality metal polish or protectant to maintain their shine and prevent tarnishing or oxidation.
Grip Replacement: Replace worn or damaged handlebar grips as soon as possible. Deteriorated grips can compromise your control and comfort while riding.
Handlebar Inspection: Regularly inspect your handlebars for any signs of damage, such as cracks, dents, or excessive wear. Replace them immediately if any issues are found, as damaged handlebars can pose a serious safety risk.
Winter Storage: If you store your motorcycle during the winter months, consider removing the handlebars and storing them in a dry, climate-controlled environment to prevent corrosion or damage from moisture and temperature fluctuations.
Professional Assistance: If you're unsure about any aspect of handlebar maintenance or encounter any issues, don't hesitate to seek assistance from a professional Harley-Davidson mechanic or technician.

By following these maintenance and care tips, you can ensure that your new handlebars remain in excellent condition, providing a comfortable and safe riding experience for years to come.

Frequently Asked Questions

How difficult is it to change handlebars on a Harley?

Changing handlebars on a Harley-Davidson motorcycle is a relatively straightforward process for those with basic mechanical skills and the right tools. However, it does require some patience, attention to detail, and adherence to the manufacturer's instructions. The level of difficulty can vary depending on the specific model and year of your Harley, as well as the type of handlebars you're installing.

Will changing handlebars affect my bike's handling or performance?

Yes, changing handlebars can potentially affect your bike's handling and performance. Different handlebar styles, widths, and heights can alter the rider's posture, weight distribution, and control inputs. It's essential to choose handlebars that are designed for your specific Harley model and riding style to ensure optimal handling and safety.

Do I need any special tools or equipment to change handlebars?

While the basic tools required for handlebar replacement may vary slightly depending on your Harley model, you'll generally need a set of wrenches, pliers, a torque wrench, and possibly a handlebar puller tool. Having a service manual specific to your bike can also be helpful for reference.

How long does it typically take to change handlebars?

The time required to change handlebars can vary depending on your experience level and the specific bike model. For an experienced mechanic or a DIY enthusiast who has done this before, the process can take anywhere from 1 to 3 hours. However, if it's your first time, you should allocate more time to ensure you follow the instructions carefully and don't rush the process.

Can I install any type of handlebars on my Harley, or are there restrictions?

While there are many aftermarket handlebar options available, it's crucial to choose handlebars that are designed specifically for your Harley model and year. Installing handlebars that are not compatible or approved by the manufacturer can compromise the bike's handling, safety, and potentially void your warranty. Always consult with a Harley-Davidson dealer or reputable aftermarket supplier to ensure compatibility.