Motorcycle Handlebar Replacement Procedure! From Basic Steps to Precautions, and an Estimate of Labor Costs for Bringing It to a Shop

Two main types of motorcycle handlebars

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By replacing your motorcycle's handlebars, you can achieve a riding position that suits your height and riding style.

Motorcycle handlebars are broadly divided into two types: clip-on handlebars (sep-han) and bar handlebars. Bar handlebars also include ape hanger handlebars. It's best to choose one that suits your physique and desired style.

Clip-on Handlebars

Clip-on handlebars (sep-han) are handlebars where the left and right sides are independent. They are often found on sporty motorcycles like racing models.

The advantage of switching from bar handlebars to clip-ons is that you adopt a more forward-leaning posture, which reduces air resistance. Additionally, the adjustable position and angle of the handlebars make it easier to customize them to your body type.

Conversely, the disadvantages are that the forward-leaning posture makes it more tiring than with bar handlebars, it's harder to maneuver the bike when dismounted, and in the event of a fall, the handlebars can hit the tank or other parts, potentially causing greater damage.

Bar Handlebars

Bar handlebars are single-piece handlebars commonly found on naked bikes and off-road motorcycles.

Bar handlebars are positioned higher, offering a natural riding posture, which reduces fatigue during long rides. They are also easier to maneuver by pushing the bike compared to clip-ons.

The disadvantage is that the angle and position of the handlebars cannot be adjusted as finely as with clip-ons, which might make it difficult to achieve your preferred riding position.

Ape Hanger Handlebars

Ape hanger handlebars refer to a type of bar handlebar that is higher than the stock bar handlebars.

The advantage of ape hanger handlebars is that they allow for a more upright posture, reducing strain on the shoulders and lower back. They also provide a better field of vision, making them less tiring than stock bar handlebars on long rides.

The disadvantages are a loss of sportiness and increased wind resistance, which can make high-speed riding more challenging.

What changes when you replace motorcycle handlebars?

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While stock motorcycle handlebars are designed for universal comfort, they may not be tailored to individual body types, which some riders might find uncomfortable.

Replacing handlebars is an effective way to achieve a more suitable riding position or change the bike's style. But what specific changes can you expect when you replace your handlebars?

Ease of Riding

Replacing your motorcycle's handlebars can improve rideability by allowing you to achieve a position that better suits your body type.

If you currently have bar handlebars and prefer a more forward-leaning posture, clip-on handlebars offer fine-tuning of angle and position. If you want to raise the handlebars higher, consider ape hanger handlebars.

Achieving a riding position that suits you not only improves rideability but also changes the overall riding experience.

Aesthetic Appeal

One of the joys of replacing handlebars is how it tightens up the bike's appearance, making it look more refined and stylish.

Swapping stock steel handlebars for aluminum ones instantly elevates the premium feel around the handlebars, significantly changing the visual impression.

Furthermore, handlebars treated with anodization (a process that forms a film on the aluminum surface) will enhance their beauty with the unique colors produced by the anodizing process.

Maneuverability

Raising the handlebars by replacing them can make the motorcycle easier to maneuver.

Conversely, replacing bar handlebars with clip-ons and lowering them can make it harder to push the bike when dismounted. Also, turning the handlebars full lock might pinch your hands between the handlebars and the frame, making maneuvering more difficult.

What you need to replace motorcycle handlebars

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To replace your motorcycle's handlebars, you will need several types of tools, such as the following:

• Replacement handlebars
• New grips
• Wrench (8-12mm) / Hex (Allen) wrench
• Screwdriver
• Center punch
• Electric drill
• Metal and rubber adhesive

Replacement Handlebars and Grips

Prepare the new handlebars you intend to install.

While you can reuse the old grips, it's recommended to replace them with new ones when changing handlebars. Grips are a direct contact point and made of rubber, so they are prone to dirt and wear.

Precautions when replacing grips

For models equipped with heated grips, the grip and heater controller are often integrated, making it impossible to replace only the grip.

Be aware that if the controller and grip are integrated, you will need to replace the entire unit.

Wrench (8-14mm) / Hex Wrench

You'll need an 8mm to 14mm T-handle box wrench for attaching/detaching handlebars, clutch lever holders, and brake master cylinders. (For Japanese motorcycles)

Additionally, depending on the model, you might need a hex wrench for removing parts around the handlebars or the clutch lever.

Screwdriver

A (Phillips) screwdriver is used for attaching and detaching turn signals and throttle assembly components.

A flathead screwdriver can be used to remove grips from the handlebars if you plan to reuse them, but it tends to scratch the handlebars.

While it's generally advisable to replace grips with new ones when changing handlebars, a flathead screwdriver can be useful if you only plan to reuse the grips and not the handlebars themselves.

Center Punch

A center punch is a tool used to create a guide (mark) before drilling holes in the handlebars, ensuring the holes are accurately placed.

When drilling, the guide created by the center punch prevents the drill bit from slipping, allowing for precise hole drilling.

Electric Drill

An electric drill is used to create holes in the handlebars for mounting switches.

When replacing with aftermarket handlebars, they often don't have pre-drilled holes for switch mounting, so you'll need to drill them yourself. An electric drill is necessary for this task.

Switches attached to handlebars typically have a small projection (a positioning lug) to prevent them from rotating. You'll need to drill these lug holes, paying attention to the orientation and angle of the switches.

Metal and Rubber Adhesive

Metal and rubber adhesive is used to secure the grips to the handlebars.

Any metal and rubber compatible adhesive, such as Konishi Bond G17, will work, but using a grip-specific adhesive is safer as it offers better vibration resistance and hardens even without air exposure.

Steps for Replacing Motorcycle Handlebars

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In this section, we'll explain the steps for replacing handlebars for those considering it.

If you're thinking about replacing your handlebars or attempting it yourself, please use this as a reference.

Step 1: Remove peripheral parts from the stock handlebars.

First, remove the peripheral parts attached to the stock handlebars, such as the turn signals, brakes, clutch, switch assemblies, and master cylinder.

The removed parts could damage the frame, cowling, or fuel tank, so protect them by wrapping them in rags or cushioning material.

If you plan to reuse the grips, remove them at this time. It's easiest to remove them by spraying parts cleaner between the grip and the handlebar and gradually peeling them off with a seal remover.

Step 2: Remove the stock handlebars.

Once the peripheral parts around the handlebars, such as the turn signal switch, are removed, loosen the bolts securing the handlebar holder in the center of the handlebars and remove the stock handlebars.

If the grips have been removed, it's a good idea to place cushioning material or work gloves on the ends of the handlebars to prevent them from hitting and scratching the fuel tank or other parts.

Step 3: Drill holes in the new handlebars.

Next, drill holes in the new handlebars for securing control switches like turn signals.

Control switches have anti-rotation lugs, so you'll drill corresponding holes in the handlebars. First, temporarily install the controls after fixing the handlebars to check the angle and position.

Once the position of the controls is determined, mark the drilling location on the handlebars and remove them. However, drilling directly might cause misalignment, so use a center punch to create a guide.

Step 4: Temporarily fasten the new handlebars.

After drilling the holes in the new handlebars, temporarily fasten them and adjust the handlebar angle to your preference.

The riding position changes with the handlebar angle, so find an angle that suits you well.

Step 5: Reassemble the surrounding parts.

Once the handlebars are secured, reattach the surrounding parts, returning them to their original positions.

After all the surrounding parts, including wiring and cables, have been installed, double-check that they are securely fastened and that all switches are functioning correctly.

Step 6: Install the grips on the handlebars.

Once the handlebars and surrounding parts are secured, attach the grips to the handlebars.

Before attaching the grips, apply grip adhesive to the handlebars and quickly slide on the grips. Be careful not to apply too much adhesive, as it will ooze out and be difficult to clean up, so apply a thin layer.

Also, when attaching the right-hand grip, ensure there's a small gap so it doesn't interfere with the switches or controls when rotated, as this could impede throttle operation.

Step 7: Fully tighten the temporarily fastened handlebars.

Once the grips are installed on the handlebars, fully tighten and secure the handlebars completely.

After securing the handlebars, sit on the bike, grasp the handlebars, and reconfirm that there's no wobbling and that all switches are functioning correctly.

Precautions when replacing motorcycle handlebars

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If you're replacing your motorcycle handlebars yourself, without professional assistance, there are some important points to consider before you begin.

• Will the dimensions change with the new handlebars?
• Are the cable lengths sufficient?
• Aftermarket parts often require drilling.

Check these points before replacing, and if you're not confident, ask a professional shop to do the replacement.

Caution 1: Will the dimensions change with a handlebar replacement?

If the dimensions of the vehicle (overall width, overall length, height, etc.) change beyond the specified range due to handlebar replacement, structural modification procedures must be followed.

If it falls within the specified range, structural modification procedures are not required.

Caution 2: Are the cable lengths sufficient?

To avoid the situation where cable lengths, such as for the brakes, are insufficient after a handlebar replacement, check if the cables will reach properly before making the change.

The cables to pay attention to when replacing handlebars are as follows:

• Brake cable
• Clutch cable
• Brake hose
• Choke cable
• Main harness and electrical harnesses

Caution 3: Aftermarket parts require drilling.

When replacing with aftermarket handlebars, you will need to drill holes to prevent the control sections from moving.

You'll need an electric drill for drilling and a center punch to mark the hole positions accurately, so prepare these tools.

Estimated Cost for Handlebar Replacement at a Shop

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Replacing motorcycle handlebars yourself requires tools like wrenches and drills, and if you find it too challenging, it's recommended to ask a shop to do it.

So, what's the estimated cost for handlebar replacement if you ask a shop?

When requesting a motorcycle shop

If you request a handlebar replacement at a motorcycle shop, the average cost for bar handlebars is around 5,000 to 10,000 yen. (If fairing removal is required, an additional 1,000 to 2,000 yen will be added.)

For clip-on handlebars, it's about 8,000 to 15,000 yen, which includes the installation of handlebars, grips, bar ends, and drilling.

When bringing your own handlebars for installation

If you provide your own handlebars and ask a shop to install them, the estimated cost will be 1.5 to 2 times the standard replacement fee.

At 2Rinkan, the cost for handlebar installation with customer-supplied handlebars is 11,000 yen (tax included), which is twice the price compared to purchasing handlebars from 2Rinkan.

FAQ regarding motorcycle handlebar replacement

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This section compiles frequently asked questions and their answers regarding motorcycle handlebar replacement.

If you're considering replacing your motorcycle's handlebars, please refer to this information.

How difficult is it to replace motorcycle handlebars?

The difficulty of replacing motorcycle handlebars varies depending on your experience with maintenance and your familiarity with tools.

When replacing with aftermarket handlebars, the biggest challenge is drilling holes to secure the switches. If you have some experience with maintenance or modifications and are comfortable with drilling, it's not overly difficult.

Are there any tips for drilling holes in motorcycle handlebars?

The trick to drilling holes in handlebars is to use a center punch to create an indentation at the drilling location to prevent the drill bit from slipping.

Also, instead of immediately drilling the target size hole, start by drilling a small pilot hole and gradually enlarge it to the desired size to avoid mistakes.

Is it true that cutting the handlebars will prevent the bike from passing inspection?

If you cut the handlebars and the overall width changes significantly, your bike will not pass vehicle inspection as is.

For example, for overall width, a deviation of ±2cm from the dimension stated on the vehicle inspection certificate (light motor vehicle notification certificate) is acceptable. If the change is more than 2cm, you'll need to apply for a structural modification before the inspection.

A structural modification is an application required when a motorcycle's dimensions change due to modifications, and it must be filed within 15 days from the date of the modification.

What are the benefits of switching to ape hangers?

The benefits of switching to ape hanger handlebars are reduced fatigue during long rides and improved maneuverability.

Ape hanger handlebars allow for a more upright, natural riding position, which also raises your line of sight, expanding your field of vision and making you less tired.

What are the benefits of switching to low handlebars like clip-ons?

The advantage of switching from bar handlebars to lower handlebars, such as clip-ons, is that the forward-leaning posture reduces wind resistance.

The combination of a forward-leaning posture and a lower center of gravity makes weight transfer easier, especially during sport riding on winding roads or race tracks.

What cables need to be extended when replacing handlebars?

As mentioned in the precautions for handlebar replacement, there are cases where cables may need to be extended.

The cables that might require extension are as follows:

• Clutch cable
• Brake cable
• Throttle cable
• Choke cable
• Switch harness, electrical harnesses
• Brake hose

Harnesses need to be the correct length, as they may not function properly if they are too long or too short.

How much does it cost to have Red Baron replace handlebars?

If you have Red Baron replace your handlebars, the replacement cost is approximately 8,000 to 12,000 yen.

This is for the handlebar replacement labor only. If you're installing aftermarket handlebars, separate processing for switch mounting holes will be required, adding about 4,000 yen to the handlebar replacement cost.

Summary

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We've covered everything about motorcycle handlebar replacement, from the basics of different handlebar types and the changes they bring, to replacement methods and estimated costs when entrusting the work to a shop.

By replacing your handlebars, you can achieve a riding position that better suits your physique and preferences, and also enjoy a change in appearance.

If you're replacing aftermarket handlebars yourself, you'll need to drill holes for control switches like turn signals. If you're not confident, it's best to ask a shop to handle the replacement.