HOW TO INSTALL DIRT BIKE HANDLEBARS

Step by Step Instructions to Help Make The Process Easy

Handlebars are one of the most important components of a motorcycle, they are the what allows you to control direction, lean angle, body position and much more. From time to time they need to be replaced and we are going to give you the proper techniques and tips to make the job easier.

The first step is to figure out what bar bend you need for your size, height and particular style of riding. There are three main factors to consider when purchasing a new handlebar, the width, the height and the sweep or pull-back of the handlebar.

mechanic holding new set of handlebars — Jason talks about how to determine the proper width for your handlebars

Determining the proper width to is aided by cut lines on the handlebars to ensure an accurate and even cut at the width you desire. Wider bars generally provide more control but depending on where you ride and the conditions you ride in you may want to adjust the width of your bars. For instance Eastern woods riders will want a narrower bar than a motocross or desert rider to be able to navigate through tight trees.

handlebar with cut marking lines — Handy cut lines on most handlebars make getting the lengths exactly right

When you go to cut the bars use a sharp hacksaw and mark your cut lines with tape to be sure you get a straight even cut on both sides. Use a file or Dremel tool to remove any burrs or sharp edges, especially on the throttle side.

Handlebars with complete controls and handguards — Be sure to leave room for controls, hand guards, mirrors, GPS mounts and switches you need to mount on the handlebars.

The second factor you need to consider when purchasing new handlebars for your bike is the sweep of the handlebars. Sweep is the amount of pull-back the handlebar has. The final factor in selecting a set of handlebars is the height of the bar.

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Handlebars being measured for height — The final factor in selecting a set of handlebars is the height of the bar.

PRO TIP: Take out your phone and snap a few photos of the controls before taking them off the old bars, make sure to capture how and where the cables are routed and secured. This will save time when setting up your new handlebars.

Taking a photo of control set up on handlebars — Take photos of the controls before taking them off, make sure to capture how and where the cables are routed and secured

To remove the existing handlebars you need to first remove the handlebar pad, then the clutch and brake perches and then any switches on both sides of the handlebars. Next loosen the throttle housing but don’t try too take it off, the throttle cables are usually too short to make that possible and it comes off easily after you remove the handlebar clamp.

Mechanic with wrench removing brake perch — Jason removing the throttle housing and brake perch from the handlebars

Once the old handlebars are off the process is simply reversed. Start by slipping the throttle housing onto the new bar but don’t tighten it down yet.

Mechanic placing throttle housing onto handlebars — Don't tighten the throttle housing until after you have positioned the bars in the clamps

Now line up the handlebars in the center of the handlebar clamp using the guides provided on the bars and tighten them down finger tight.

Positioning the handlebars in the handlebar clamps — Installing the handlebars in the proper position is easy with centerline markings

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Next you need to actually sit on the bike and adjust the handlebar position to your liking before loosely tightening the handlebar clamps down. Don’t do the final tightening on anything just yet, wait until you get all the controls and switches back in the proper position on the handlebars first.

Rider sitting on bike to position controls — Sitting on the bike is necessary to ensure handlebars and controls are properly positioned

Next you need to slip the switches onto the bars followed by the brake and clutch perches and finally the throttle housing. Be sure the brake and clutch levers do not extend beyond the end of the bars. Push the throttle housing onto the bars as far as you can then back off just a millimeter or two so it has free unrestricted play before tightening.

Mechanic adjusting levers on handlebars — Be sure levers do not extend beyond the end of the handlebars

PRO TIP: Use the throttle side grip to position the throttle housing, it has a larger diameter and slips right on and off the bar to help you measure and get the proper position.

Now it is time to get all the levers in their final positions, this requires you to sit on the bike and make the final adjustments. Be sure to see how the bars and levers feel in both the standing and sitting positions.

Rider sitting on bike making final adjustments to controls — Final positions of handlebars and controls is a matter of personal preference

When you are happy with the position and feel of the set up then proceed to tighten down both the clutch and brake perches and finally the handlebar clamps.

Mechanic uses t-handle wrench to tighten bolts on handlebars — A nice set of T-handle wrenches make jobs like this much easier

Once we have the handlebars mounted in place it is time to install some grips. The first step is too clean the surface of the handlebars so that the grip gets good adhesion.

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PRO TIP: Use clear spray paint to mount your grips. It provides enough liquidity to slip right on and then becomes sticky and helps hold the grips firmly in place when it dries. Spray a small amount of paint in the end of the grip and a small amount on the end of the bars. Then push the grip on fully. Make sure the grip is on straight and not twisted before the paint starts to set.

Mechanic holding can of spray paint for mounting grips — Use clear spray paint to install grips quickly and securely

PRO TIP: On the throttle side use an aftermarket throttle tube, this makes it unnecessary to remove the throttle side grip from the stock throttle tube and leave behind messy glue and residue. Just mount the new throttle tube to the throttle housing and then install the new grip in the same way as the clutch side grip went on.

Mechanic holding an aftermarket throttle tube — Using an aftermarket throttle tube make life much easier when replacing grips

The final step in setting up your new handlebar is to safety wire the grips into place for extra security. Use a set of specialized safety wire pliers to install three strands of of double looped 32/1000 brass safety wire on each grip,

Mechanic using safety wire to secure grips — Always safety wire your grips to be sure they don't come loose while riding

The pliers make it much easier to twist the wire and secure it without breaking it off. Finally clip off the excess wire to about 1/4 inch and then carefully tuck it into the grip in the rear facing direction so it doesn’t catch on your gloves.