Stock photo of my bike.
This is the fist I have made a post like so here goes...
There are probably a few ways to accomplish this task, I am just going to show and discuss the way I did it. I hope this someone considering installing their own bars.
Before you start, make sure the bars you receive have the hand control alignment holes on the top.
Start by protecting your gas tank and front fender. I used thick beach towels. That’s about as thick as you can use because you’ll be sliding the bars in and out between the bottom of the dash and the top of the gas tank. It’s a tight fit. Remember to use loctite or a similar product on your bolts.
Raise the windshield up all the way.
Remove the headlight trim and headlight assembly.
With this method you only need to unplug one large (there are two) grey plug. As you’re looking at the front of the bike, its the one on the left side.
Remove the small bolt on the brake line bracket.
Remove your brake (right side) assembly by removing the two screws on the clamp. If you have a crash bar, clamp it to the bar for safe keeping. If you don’t have a crash bar, you’ll need to suspend it in the air so you don’t put unnecessary stress on the line and keep it as level as possible.
Remove the housing from the clutch (left side) side. There is a small plug that is attached to the clutch lever that you’ll need to unplug from the assembly before you can take it off the bars.
I used a small pick style tool to push in the tab and push out the plug at the same time.
Remove the clutch (left side) assembly from the bars by removing the two clamp bolts. You can let this one hang in the air or tie it up as well.
Remove the two 17mm riser bolts.
Once you have the riser bolts off, the bars will rest on the gas tank. You can pull the grey plug (unplugged earlier) back toward the tank and carefully pull the bars out. It will take a little work, turn the fairing as your sliding the bars towards you to the right side of the bike.
Grey plug mentioned earlier.
Bars side by side. Don’t completely unwrap your new bars yet, they can get scratched as you work the cable through them and start reassembly. If you want to check them out before starting make sure you rewrap them for this part of the install.
Remove the electronics housing. Take pictures of where your plugs are on each side. If you don’t currently have heated grips, you’ll have an extra white plug with pink and black wires on each side. These just lay inside the bars for future use.
Do the throttle side first, its the harder of the two sides. On your old bars, feed the throttle side cable through toward the throttle control assembly enough to clear the plug so you can unplug it from the rest of the wire assembly.
Pull the wire assembly from each side through the old bars.
Spray a light to medium amount of WD-40 or a similar product inside the new bars. This will help the wire assembly slide through a little easier.
I used a long piece of twine to feed through the new bars. Tie two small sockets or whatever you have to weigh down the end of the twine. I needed more than one as one was not heavy enough to work it’s way through the bars. Also, space the two objects about one inch apart, this will help them make the turns on the way though the new bars.
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