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Changing handlebar instructions (Read 167 times)
blacksheep23
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Changing handlebar instructions
07/31/08 at 17:32:07
 
Can anyone that have change their handlebar write instructions on how to change one.Step by step including pics.I just got the handlebar and I want to make sure I do it right!

Help pls.
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Brad_THMP3R
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Re: Changing handlebar instructions
Reply #1 - 07/31/08 at 19:12:16
 
Dude, it's really straight forward.
1. pop off the end caps
2. unbolt the clutch and brake perch
3. unscrew the switch boxes
4. unbolt the risers and remove everything.
5. put it all on in reverse order (watch out for the locater pins in the switch boxes. you can drill em off of file them. or just drill your new bars.)
6. mount the bike and grin Grin it will feel like a different bike completely

Good luck
I did mine in about 30 min and it was my first time. I used a drill bit slightly larger than the locater pins and held firm and just drilled them off.
RSD
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strangeling
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Re: Changing handlebar instructions
Reply #2 - 07/31/08 at 20:38:20
 
Isn't there a copy of the Clymers manual floating around on this site somewhere ? Because that will help you out a lot Blacksheep.
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verslagen1
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Re: Changing handlebar instructions
Reply #3 - 07/31/08 at 20:41:02
 
righty tighty, lefty loosey
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blacksheep23
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Re: Changing handlebar instructions
Reply #4 - 08/01/08 at 09:38:19
 
thanks guys.I'll try and do it this wkend and take some pics.!
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Demin
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Re: Changing handlebar instructions
Reply #5 - 08/01/08 at 11:29:12
 
Put rags over your gas tank,and frontend.So you don't nick/scratch anything.                       Just in case,ask me how I know. Wink
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savagejoe
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Re: Changing handlebar instructions
Reply #6 - 08/02/08 at 00:08:03
 
I just put new bars on mine thursday and it was really easy.  first time to. it took about 20 mins.
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aebooze
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Re: Changing handlebar instructions
Reply #7 - 08/02/08 at 08:38:15
 
I've been thinking about changing mine out.  I've got an 82 virago that I'm parting out.  I want to steal those bars for my s40.
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rigidchop
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Re: Changing handlebar instructions
Reply #8 - 08/02/08 at 08:42:27
 
didn't virago's have 7/8 inch bars? if so you better keep looking, savages are 1 inch.
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Demin
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Re: Changing handlebar instructions
Reply #9 - 08/02/08 at 10:03:22
 
rigidchop,you are right.The Virago bars won't work on the Savage.
                                          7/8"                                      1"
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Next project:finish '87 Savage custom/bobber/CHOP STYLE***DONE
finish '77 Yamaha XS650 bobber Bought another one
finish'79 Harley custom bobber(NEXT)
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aebooze
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Re: Changing handlebar instructions
Reply #10 - 08/02/08 at 10:44:43
 
darn.  well, good to know before try and take stuff apart.  thanks
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1st2know
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Re: Changing handlebar instructions
Reply #11 - 08/02/08 at 11:40:28
 
For removing the left grip, dip a long, skinny screwdirver in to some isopropyl alchohol and stick it in between the grip and bar. Do this about three times - the  alchohol will act as a lubricant, and evaporate in a few minutes after you remove the grip.

Using soap will also lubricate it, but it leaves a residue and may cause the grip to slip forever(and ever).

When putting the bar back on, and zipping the wiring to the bar, test to make sure you can turn the bar freely in both directions. You dont want the wiring to stop the fork while you're slowly turning a corner - it's very embarising to lay it down high side at 4 mph.  Especially the part where people come running over to ask "R U OK?"  and  I'm  swearing at a zip tight. Embarrassed
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