Step by Step Harley Sportster Handlebar Swap
Вставка
- Опубліковано 7 сер 2024
- Step by Step Harley Sportster Handlebar Swap
We’re back at it in the garage and wrenching on the 2014 Harley Iron 883. On this episode we show you step by step how to swap out your stock handlebars for a set of taller bars. We install the Todd’s Cycles 12” strip bars with the Burly Cable and wire extension kit and a set of Arlen Ness grips. I hope this helps as you customize your Sportster too. If you find this helpful, please hit like and consider hitting subscribe to follow along on this crazy journey.
As promised, I included the torque specs that I found in my owner’s manual:
Thumb controls housing 35-45 in.- lbs.
Hand controls mounting bolts 108-132 in.- lbs.
Clutch cable at primary 36-108 in.-lbs.
Primary cover bolts 100-120 in.- lbs. (tighten in an opposing pattern.)
Riser clamp on bars 12-18 ft.- lbs.
Tank bolt 15-20 ft.- lbs.
Banjo bolt (at both the master cylinder and the caliper) 14-18 ft.- lbs.
Bleeder valve screw 35-61 in.-lbs.
Please do your own research and verify all information in this video before working on your bike. This video is for entertainment purposes only.
As always, thanks for watching. I appreciate it more than you would know! Let me know if you liked it with the "thumbs up" and consider subscribing if you want to see more. Be safe and be well. I'll see you on the next one!
Here are links to the parts I used in this video. I am not affiliated with these manufacturers or Revzilla. I'm not getting paid to recommend them to you, but feel free to use this as a reference. Always make sure that bike specific parts are configured with your make and model! If you try do your own handlebar swap, let us know how it goes in the comment section!
-Todd's Cycle 1-1/4" Strip Bars www.revzilla.com/motorcycle/t...
-Burly Cable and Wire Extension Kit www.revzilla.com/motorcycle/b...
-Arlen Ness Fusion Grips www.revzilla.com/motorcycle/a...
-Namz Ready to Install Harness Extensions www.revzilla.com/motorcycle/n...
-Namz Braided Flex Sleeve www.revzilla.com/motorcycle/n...
=====Social==Media=====
Instagram / kbelanger28
=====Camera==Gear=====
Main Camera www.sony.com/electronics/inte...
Main Lens www.sony.com/electronics/came...
Product and Macro Lens www.amazon.com/7artisans-60mm...
Shotgun Microphone www.rode.com/microphones/vide...
Lav Microphone www.boya-mic.com/lavaliermicro...
Gimbal www.dji.com/osmo-mobile-3 - Навчання та стиль
lol.. i search for a sportster video to learn how to swap the handlebars.. And of course this video has my exact bike as an example.. awesomeness
You da man, thank you for this... perfect amount of detail with zero frills, this is a pure meat n taters video for the DIY man in his garage. Stay safe, ride free from Jimbo in Pa
Haha this is my favorite comment. "Pure meat n taters video."
Great video. I'm about to do a handlebar swap on my old sportster which my daughter will be my daughter's first bike. An old trick for adjusting the clutch cable is to put a dime in the clutch lever gap to get the correct amount of slack in the cable.
Thanks bud! I'm getting ready to change out mine this morning on my first bike. '02 Sportster 1200 custom. Fingers crossed I don't need new cables.
Good video good explanation on the small stuff as well. I am installing on a Dyna but the wiring, time, parts needed is spot on.
I’m changing bars real soon, this video is crazy helpful! Thanks for the help!!💪🏼🤟🏼💪🏼🤟🏼
Hell yea brother! I love the changeover! Exactly what I was looking for!
Good idea taking pics of the lines 👌
Very well done - thank you for sharing!
Great video, very detailed. Well done from a fellow mass resident 🤙🏽
Thanks for the feedback. Thanks for watching.
Awesome video man, detailed and clearly explained. Have everything to change my bars for a few months now but been lazy, this inspired me to get it done ☑️ thanks again and ride safe. Best
Liked and subscribed..also saved the vid for reference. Really like the ease of the Namz plug & play can/bus extension but didn’t see a kit for Sportster on Revzilla or Namz site? Did you purchase another bike model? Also what length, 12-inch cable extension?…going to install Burley narrow bottom apes…seems like this could be done in a weekend taking your time. Thank you!..
I'm glad you enjoyed it! Good luck!
I did buy them on RevZilla. They were a model specific part and RevZilla confirmed that it fit my bike... But when they sent it, it was actually labeled to fit a mid 2010's Softail. So, it must be a pretty universal fit for many bikes. Just make sure you save your bike into RevZilla and they should confirm that the suggested part will fit your bike automatically before you put it in your cart.
It's part #1141712 on 'Zilla. I went with the 12" and had plenty of length.
@@TheJourneyUA-cam thanks again for your time to make the video and respond to my questions 👍
Nice one, this one really clear information
This truly helped me out. Thank you!
You're welcome! Ride safe.
Your use of aperture on the intro where youre speaking is fabulous. Seems like you know your camera as well as you know your Bike. This vid is informative.
Thanks for the comment. I do what I can!
@@TheJourneyUA-cam Im tryin to learn to get away from usin my iPhone for content on my channel. Learnin this Nikon is a TRIP ! Haha
@@jayteesgear I started on my phone too but the real camera gives you so much more control. Good luck, it can be as complicated or as simple as you let it be!
My guy! Thank you 🤘🏻
If u get Burly Brand, DO NOT OVER TIGHTEN THE CLUTCH CABLE!!!! They break off all the time. I put them at “finger tight”. Lol. Great video!
Thanks for the tip! I'm glad you enjoyed the vid.
what exactly breaks?
I have a 2020 Iron. I hope it fits on mine! Love this setup! And great content!
Thanks!
Did it fit ?
Where can I find these 10” cable replacements ??
Hey I'm going from 2020 iron stock to 12 inch apes... do I need cable extensions ??
@@Tyrell69 yes you do
If your sportster has an alarm, you want to turn the ignition to "ON" and then pull the main fuse. When the job is completed reconnect the fuse and turn the ignition off. Keep the fob within a few feet of the bike the whole time.
Nice ride. Like the idea of snaking the wires through the bars using the casing.
Now get out and ride and be safe.
See you on the road! 👍
@@TheJourneyUA-cam nice video bro.
I got a question for you.would I still need to depin the turn signal wiring if I already relocated my signals on the forks?
@@fromp.itohawaii277 I'm not in front of my bike, but I'm 99% sure that you do, especially if you want to internally wire the bars. The wire from the thumb controls needs to be depinned and extended, plus having the pins without the plastic connector makes it possible to snake through the bars.
Great video it just confirmed I will have Harley deal install my handlebars cause I aint gona F my bike up.
Awesome vid. Helpful a lot. Where I can find that print page ?
Thanks a lot .
Most thorough video seen so far on bar install for a Sportster. Good stuff. Daughter has a new-to-her 2018 Iron 883 that needs bars/grips a few inches closer, so this video is saved and subscribed. Haven't started sourcing parts yet, but a couple questions. What if you screw up the grip, glueing it on? Are we talking needing new bars, or is that glue pliable enough to work with to get off, sand and try again? Also, given the date of the vid, I expect you gave it a good amount of miles this past spring and summer. Any adjustments or problems after the install?
Thanks for the comment. I'm glad the video helped you. I have footage of a bar review after 500 miles. I'll be posting that in the next week or two. In short, everything has been just about flawless with the bars. I think I adjusted the clutch just out of preference and that's it. Regarding the grips, if you screw it up you will need to cut them off and buy new grips but just sand the bars and you can keep installing new grips for as many times as you like. Just remember to put most of the glue to the inside of the grip and not that bar so the glue stays in the grip and doesn't get pushed out as easily. Also keep an eye on the end cap so it's aligned. Grips are very easy. Good luck!
So im looking at doing the same on my bike with the chiseled bars from harley would you say I'd be good with the 4" wire extension kits I have a 22 iron 883
Love the infamous "Bubba Scrub" poster😀
Getting ready to remove the drag bars of my fat Bob and install apes. Been worried I can’t do it myself. Hopefully this video helps
Let me know how it goes! I think you'll be fine!
Very nice video, like the torque specs info a lot, good production, you might need a better mic@, but this was awesome
Thank you! I'm glad you liked it.
Great video! I am in the beginning stages of bobbing a 1988 sportster 1200. Definitely leaning toward this setup. Do you think the process for mine will be pretty much similar to yours?
Yes it will absolutely be similar. Harley hasn't changed all that much about this bike since the mid 80's...
Does the throttle cable or the return cable take the cable with the spring?
You wanna do my bars bro I’d love to come to you, polite and detailed.
What size extension harness for 16in?
What diameter brake throttle clutch sleeve did you use?
Did you have a hard time with bleeding the front brake? It seems as if my burley extended brake line, and the stock banjo bolts aren’t lining up.. I installed the new copper crush washers as well, used stock banjo bolts (burley kit didn’t come with any) and after struggling with not getting any fluid into the system, from the reservoir, to the caliper, I realized my banjo bolt flow holes, aren’t lining up with the brake line holes.. therefore fluid is not flowing from the reservoir into the line, down to the caliper.. any suggestions? Or tips?
I'm not sure if the banjo bolt and brake line holes need to align. I did have to pump my brakes hundreds of times before it started flowing though! Maybe you just need to keep on pumping, or get a vacuum pump and it should go quicker. Keep at it for a while before buying new cables or bolts. It's a pain in the...
Great video, can you please share the link from where I can purchase these exact same bars.
Yes sir. The bars are the first link in the description under the video.
Hello when you replaced the cables on the sportster and you placed the clutch cable in the primary, there was a nut that you put on and then the screw thru it and backed off the screw. My question how tight did you tighten that nut., it looked like just hand tighten. It happens around 15:35 in your video. Thanks, Kenny by the way GREAT video
You don't actually need to tighten it. That nut is threaded on the inner rod that you make the final adjustment on. It will make total sense once you take it apart as the only way to remove the nut is to turn the inner rod and the nut backs itself out. I hope that makes sense.
@@TheJourneyUA-cam Thanks man, thats kinda what I figured, but kinda figuring in the past caused me some problems, so now I ask first 😁. Bro if everyone made vids as thoughtful as you we would all be better off. Thanks again for the fast reply
@@coralparadise323 thank you. If you think it's a worthwhile video, hit the thumbs up so UA-cam knows to suggest it to other people. Good luck with your project.
Hello brother i have a 2019 xl883n sporter. I planning to go with the 14” handlebars swap but I see the my brake lines come together with the back brake lines as well.. is there a good cables kit that you can recommend for me? Thank you i enyoy watching your videos..
I've been happy with the Burly cable kit. They make a 14" version. I'm not familiar with the brake line situation that you speak of.
👍👍
What if you're not internally wiring your cables? Would I still need an extender for my controls? I have a 12 inch bars that I am putting in and I have the burly cables for 12 inch.
Even if you don't run the wires internally, you will still want to keep them in line with the bars, so I would say that yes, you will still need to extend the control wires. Good luck 👍
Namz Ready-To-Install Handlebar Extension Harness For Harley you get the 8 12 or 15 length??? I'm putting 10 on my 883 iron
I got 15" for my 12" bars. You should be good with the shorter ones. If there's a little extra play, you can just hide it inside the bars. It's better than coming up short! You might be close to not needing them, though. A lot of guys can go up to 8" rise without extensions.
If I’m only putting in 6” risers would I need to still get longer cables? Or would the cables I have be long enough?
I've heard of people installing 8" bars and not needing longer cables, so you might be OK. I would unbolt the bars leaving all of the cables intact, make a wood block to hold the bars in their new location and see if you can get away with the stock ones. If it's close, I would get longer cables and/ or wires.
Hey bud, This was great. Thank you! -Was wondering if I could quickly pick your brain.. : Have a 95 Dyna Low rider. Came with Beach-style bars, wanting to swap for drag bars ( grabbed a set of Demon Cycle, 6" rise. Basic test-fit Literally puts the grips at the same position (Height, etc..) ., Just w/ forward facing grip, rather than to the side.. like almost holding a candle ). Which is why I'm doing this). My funny question, to determine if I need an 8" rise over a 6" ( to clear instrument cluster, etc..) is : On this bike, it seems I can potentially just unbolt the bars, drop them gently forward, then install the drag bars and just test. -Am I missing something?? ( occasionally brain turns into pile O gummy bears.. so second opinion would be helpful ). ((Also, have rebuilt a few older bikes, Honda's mainly, CB750's, VFR800's etc.. but this being my first HD, ..and not wanting to be 'That Guy', figured I would just ask. (Btw, All lines, Clutch/Brakes, Throttle, elec, etc.. are all in line with new bars. So literal swap, aside from soldering the controls (wiring inside bars) if the they work out.) Thanks again man for any input. Simple question, but sometimes the most important ;) Cheers and stay well out there! :)
Unless I'm missing something, it sounds like you'll be good. There isn't any mystery with bars. If the dry fit seems to work, you're good. Just turn the bars in both directions to check clearances and go for it! Thanks for following along!
@@TheJourneyUA-cam Thanks man.. really Much appreciated,. and yeah, it was one of those simple questions . . Apparently overthinking is side effect of extended cabin fever. ;) Now it's just making sure the torque specs for the lower bolts, as they fit directly into the drag bar posts, are indeed 35 ft lbs.( give or take 5ft lbs). Cheers and thanks very much again for the reply. Stay well out there!! ~j
Cam find the namz cable plug n play the link in bio take to wrong bike ? And ideo or part number for the sportsters
I just clicked on the link to the namz wire connectors in the description. It takes you to the right part, but then you just need to enter your specific year and model and RevZilla will give you the right part number. There are different part numbers depending on the year and model sportster so I can't just give one part number and have it fit all sportsters. Also, I think the part that fit my 2014 iron also fit some softails etc. So maybe that threw you off?
Great ill check it out
Much respect dude!
But I am going to pay you or another professional to do this right!
LOL
Seriously, great video and safe riding brother!
Peace
Thanks for watching and thanks for the comment. Ride safe out there!
What oil did you use for your clutch? Been reading online and some say just your normal engine oil and some say 75w90.
Honestly I bought the Harley Davidson Genuine+ Transmission and Primary lube and I just looked... wouldn't you know it, they don't put the weight/ spec on the bottle. It doesn't seem as thick as 90wt but doesn't smell like regular oil either. I've used ATF for some other bikes, but this also doesn't smell like ATF. Sorry I could be more helpful.
Great video!
I have two questions:
1. Is this height of the handlebar tiring?
2. how long did the whole conversion take you?
Thank you
The height is good for me. It isn't tiring at all for me. I have a quick video about measuring for proper handlebar height. It isn't perfect but it might be helpful for you. Also, it took about 6-7 hours for the install including filming the video. 2 hours of that was probably just for the internal wiring.
Thank you very much! Keep up the good work!
👏
Will I be fine if I remove the primary cover without draining oil or transmission fluid ?
If you are on the stand, you will lose some fluid once you remove the primary cover and will need to add some again to get it to the proper level. If you don't lose any, you were probably running too low.
How long should I go with for 10 inch bars for the NAMZ harness extension plug n play
You can probably just use the shortest ones they offer since the Harley Z bars are 8" (they are short for an 8" bar, but still) and I've been told that the stock wires are barely long enough for those bars without extensions.
Cool thanks man, your harness looks like it came with 3 plugs from namz. The link you have under the video shows 2 wires 2 plugs. What’s the 3rd plug for?
What part number on the namz harness kit?
The RevZilla link is in the description. Just click on it, enter your year bike and length bars. That will give you the exact part to fit for bike/ bar setup.
Would this work on a 2006 sportster xl
All of the principles are the same, just be sure to order the wiring harnesses and cable kit for your model and check a maintenance manual for your bike. The wire colors might be a little different and the torque specs might be a little different too.
I was wondering what torque wrench you're using?
It's just a 1/4" in./lb. Torque wrench from Amazon. I believe it is a Tekton. It seems to work ok but I've never checked it for accuracy.
Has anyone ever put a set of ape hangers on a 1200 sportster??
I kind of only want to see the actual plug and play part as obvious as it may be I really need to see it
So I did everything you did in the video but now my sportsters clutch wont disengage when I pull in the clutch and no matter what I do or how many times I adjust it it still won't disengage. Could you help me out
It's probably an issue with the adjustment in the derby cover, not at the cable. Just look through a factory service manual about the sequence of adjusting the clutch. I thought I did a pretty good job at showing what to do, but maybe a different look at it/ a different point of view will help. There are a lot of UA-cam videos about that adjustment if you don't have a factory service manual.
@@TheJourneyUA-cam you did an excellent job in your video I've been dealing with this issue for about 2 months now and I'm completely dumbfounded
Will all this work on a 2017?? Basically the same concept on all them??
Yes I believe this is all the same for 2017. If you buy everything on RevZilla, you will enter in your bike model and year and they will suggest different part numbers if anything varies. Good luck! It isn't too difficult.
I have a 22 - iron 883 , and 10 inch z bars from Harley, would I be okay if I just buy new brake line and the plug and play kit ? And is $500 an okay deal to have a shop install these.?
I wouldn't pay a shop to install them, but that's just me. If I'm going to trust my life to my bike, I want to be sure that no one cut any corners. If you do pay a shop, they should be reputable enough to confirm that all of the parts are compatible, or don't use them. Having said that, I think I remember hearing that the 8" Harley z bars can barely get away without new cables. 10" might be tight! Good luck.
@@TheJourneyUA-cam so I had these installed and had it for about a month , the only regret now that I have is I wish I would have gone just a little higher maybe 12 or 13 , could I install risers to make them a bit higher ? And if so what size do you recommend ?
@@joeyl3153 you can definitely add a riser of your choice. I don't have any experience with them on my bike though so I don't have a specific recommendation.
Great video.
Do a tank lift &
Wire tuck.
Get of those plastic
Shields
Great job
You have links for everything? I want this exact bar setup on my sportster
I can post links to everything I bought in the next day or so. They aren't affiliate links so I don't get any kickback, but feel free to order from the links. Just make sure everything that's bike specific fits your year.
Check out the video description. These are the parts that I used for the job! Thanks for watching!
I installed on my 2013, 12” bars from Harley yet now I get wobble above 80mph…. Didn’t happen with the stock bars, any ideas?
Lots of ideas. Death wobble can be caused by slop in the bearings, worn out mounts,, improper tire pressure, too much or not enough weight on the front end (unbalanced bike) amount other things. If you are certain that the change happened when you changed the bars and it isn't a coincidence, maybe it's because you've changed your posture and therefore affected the weight on the front end. If it was me, I would check all of the routine maintenance items and if everything is within spec and there isn't any wear on the bearings etc., Try to adjust the pullback on the bars. You can always add a steering stabilizer but that is just hiding the real problem and not actually fixing it. Good luck. Share what you find. Death wobble is scary.
@@TheJourneyUA-cam after checking the front forks for play/ seeing if they need springs or oil, replacing tires and all that, I ordered a steering stabilizer from revzilla! And it fixed it, no more wobble and it drives straighter than ever!
@@nancearmory1509 i know everyone says that death wobble is caused by many issues that can be resolved with routine maintenance, but the consequences can be so dangerous from death wobble that I've considered a stabilizer just in case. Better safe than sorry! I'm glad it worked for you.
What bars are those, since you put nothing in the description
Todd's cycle strip bars 1-1/4". Check the description again. I mention them in the description plus I put a link to where you can find them on RevZilla. Thanks for watching.
Can't everything just slide off the bars and be slid onto the new bars without draining the brake fluid and taking the cables off?? Or no? First bike so excuse the dumb question if it is
If you go with new bars that have a similar rise, you can skip the brake line and clutch cable replacement steps, but you will still need to snake the wires for the thumb controls and turn signals through the bars if you want the wiring to be hidden. If you go with a rise that is 8"-10" or more, you will need to do everything.
@@TheJourneyUA-cam ok thanks. I'm going from straight drag bars the previous owner had to 8" rise... fingers crossed... sounds like I may need new lines
They did leave the extra line from the stock bars when they went to drag bars. So I'm hoping I get lucky
Is that a 1.25 inch diameter bar? I think my stock riser is 1 inch. (2016 883 Iron)
These are stepped bars. They are 1.25" but they step down to 1" at the riser clamp and at the controls/ grips. I was able to use my stock riser on this 2014 iron. It should fit yours too.
@@TheJourneyUA-cam cool beans man. Safe riding
@@vinny9988 thanks for watching. Good luck.
Any chance you wanna sell the original handlebars and cables?
I will have a stock set of bars available for sell in a week. Hit me up for the link.
Did anyone break the clutch cable when installing it. I broke mine. I'm really screwed now. I'm gonna have to send Burley a negative review. The cable on the bolt side is really fragile. Now I'm stuck trying to drill out the thread that's stuck on the housing plate. FML
What year model is this bike
2014
I also hate soldering
I was told with 10inch bars I wouldn't need to do the cable extensions
That's right on the edge. There's no standardized measurement for bar size so you might be ok but you might not depending on the manufacturer.
@@TheJourneyUA-cam this looks complicated I'm kinda nervous
@@iiviinstiinct3064 you got this. Just make a parts list, buy a repair manual for torque specs and do your research before you start. I'd like to think that my video is a good start for you.
What about bleeding the brakes?!
Thanks, man. I mention it at 18:18 but don't go into detail. There are a lot of videos on UA-cam on how to bleed them, but I can make a video too if enough people are interested.
YO I CAN NOT GET MY CLUTCH CABLE TO THREAD IN WTF LOL. and I know I got the right cable it’s burly brand and for my make and model and year of my bike
You probably have the right cable but those suck to get started because it's a fine thread and the cable is curled so it is hard to get aligned. It took me a few minutes to get it started. Maybe ask someone if they can hold the end of the cable to help you go straight to the clutch case. Good luck.
For some reason my clutch isn’t righting is there a reason why?
Righting?
@@TheJourneyUA-cam tightening*
@@TheJourneyUA-cam it doesn’t spring back the lever stays loose
Every time I pull the clutch the wire in the primary pulls and stay it doesn’t snap back
@@TheJourneyUA-cam also too it’s able to change out of neutral without the clutch but not back to neutral
You're killing me with the lack of walk around footage/before and after.
that music is too loud, we can't even hear you sometimes
trying to focus so you don't spoil a thing with all that noise is really hard
Send me your old bars
Why is it no one wants to show how to actually change the throttle/idle cable at the carb? Just a general “how to” what the fuck? You literally showed nothing.