xxabyte

Hi all, im a newbie just have a quick question. it is easy to replace the handle bar (or highway bar?)? i know how to use the wrench but that about it. thanks!

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GearJammer

Welcome, xxabyte....

Are you looking to change stock handlebars for a better set of stock handlebars or are you wanting to install a different style of handlebar ?

Reason I ask is that stock to stock would be fairly straightforward & we could walk you thru it no problem. If you're thinking about alternate handlebars, there may be issues like bar to gas tank clearance, control cable length, etc.

Please clarify & we'll go from there, O.K. ? Thanx......

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"Ridin' Ain't A Hobby, It's A Lifestyle"

1986 450 Rebel

xxabyte

GearJammer,

thanks for your replied. im thinking of changing to different style, the original one is kind of tall and makes the bike looks 'skinny'. Thanks again chief! :P

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GearJammer

So, by the original one, you mean the stock handlebars are too high & you don't care for the looks of it ?

Have you picked out 7/8" bars that you like ? If so, do you know what style they're called ?

Since you want to go with bars lower than stock (assuming the originals are stock), then you can use the same controls & cables no problem.

If I'm wrong on this part, someone please correct me, but the turn signals aren't in the way for changing out bars, right ? Going from memory on the 250 I had, the T/S's were mounted at the side of the handlebar mounts ? Which reminds me, xxabyte, is your's a 250 or a 450 ?

Near the center of the handlebars, you'll see 4 caps that are covering the allen head bolts that actually hold the handlebar clamps securely in place. Use a small flathead screwdriver & carefully pry those plastic caps off. Loosen the allen bolts a bit.

Then loosen your controls (clutch & throttle).

Turn the bars slightly downwards towards the gas tank. Remove the controls & let them hang.

Completely remove the allen bolts to remove the handlebar clamps.

Remove handlebars. Install new handlebars, tightening the handlebar clamps, but not completely yet. Re-install controls. Adjust handlebars for the right position while you're sitting in the rider's seat. Once you've got the right position for yourself, tighten the allen bolts on the handlebar clamps tightly now. Replace the plastic caps. Bingo!

The one thing you want to please remember is that you want adequate clearance between any handlebars & the gas tank so's you don't hit the gas tank & chip the paint.

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"Ridin' Ain't A Hobby, It's A Lifestyle"

1986 450 Rebel

xxabyte

doesn't seem too hard, will break it apart this weekend (wish me luck!)
Thank you for your time GearJammer.

BTW i have the 250.

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MattD

Couple of other points on handlebar replacement:

Cover the gas tank with something thick and soft(blanket, quilt, etc.) cause if you don't it will get scratched.

After you have it all put back together, if you changed the shape/size of the bars, and didn't change the cables, crank the bike, let it idle, and go from full left to full right... no speed change means you aren't putting excess tension on the throttle cable. If it increases/decreases in speed, you probably need longer throttle cables.

Good luck on the project!

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