Switching/Installing Handlebars
- Thread starter slopoke
- Start date
Pretty simple process, just takes time. Most important thing to remember is to put the throttle block on before putting the right handwarmer on. I would also cut the bars shorter by a 1/2" if you want to keep them the stock length. I also stress that when loosening the bar clamp, loosen with a wrench and not the Allen. Be careful not to lose the E clip holding the throttle cable in the block.
^^^What he said. I cut throttle side grip and (same side) grip warmer off the Pro Tapers and cut the wires so if I want those bars for something I just need to replace those parts. You will have to splice in the wires with RSI's hand warmers. I soldiered mine in so that it was clean. I too cut 1/2" off the bars and went with the long RSI bar ends and extended grip warmers.
Take off bar ends then remove brake. Loosen throttle block and move as far in as possible. Take an air compressor with a blower nozzle and stick the nozzle between the bar and the grip. blast air and pull grip off. My grip was off in literally les than 5 seconds.I used a heat gun to heat up the bar warmers. Hand warmers came off really nice, they are still fine. Once the warmers are off unbolt the bars from the post using the 10mm wrench to break nuts free. now you will be able to move the bars over the top of the sled and since the warmer is off, you can slide the throttle off the bar and don't have to mess with taking the cable off the block. That clip that holds it in the block is tiny and is gauranteed to piss you off. When putting the new bars on I undid the cross bar and routed the throttle cable through the middle just like was done on pro tapers from factory. Once the bars are on, put all controlls back on, THEN the hand warmers. Here I just heated the bars up the the heat gun, shot a little heat at the warmers and put them back on
I'll tell you why I didn't do what tyb57 suggests. First of all I got new grips and grip warmers that go out to the bar ends. But the reason I didn't blow the grip off and heat up the old warmer is that this sometimes doesn't work real well. I've done this proces about 4 times and 3 of the 4 times the rubbery substance on the warmer flaked off. You don't want to screw up your grips or you could have an issue with how your sled runs. The grips are part of the electrical circuit and if they are shorting out then so will your sled. Food for thought.
Same thing. There are marks on the bars to help with this.
