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The Handle Bars are a pretty easy
swap. Minimal tools required and I don’t remember all the sizes, but
here’s a glimpse of what you’ll need:
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Ratchet
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Torque Wrench
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Sockets
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Hex Keys or Hex
Sockets [I prefer sockets]
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Phillips Head
Screwdriver
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Loc-Tite Blue
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Grip Glue or
Hairspray
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Canned Air or
Air Compressor
Enjoy, and remember ALWAYS work safe and I assume NO
RESPONSIBILITY for your actions, mechanical abilities or
anything that may occur during the nature of the repairs.
Disclaimer: Not for
distribution, redistribution, sale, re-sale or otherwise without my
written consent. This information is presented with no liability or
guarantee expressed or implied, work at your own risk.
Copyright © Magnum / Magnum1.com 2003-2008.
Let’s get
started, first remove the stock bar ends. You might find this bolt
hard to crack loose because there is loc-tite red on the threads.
After you crack the bolt loose they will just unscrew and come off:
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Now take the
clamps off for the clutch and brake sides, these simply unscrew. I
recommend putting some towels on your upper fairings so you won’t get
any unwanted scratches. The clutch side will dangle, but the brake
side won’t go too far as it has wires that are tied to the throttle
assembly:
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Now unscrew these
two Phillips head screws on the clutch side and take the casing apart
to remove:
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Ok, here’s what
it should look like. I’m installing new grips so I did not have to
worry about removing the left [clutch] side grip, BUT if you plan on
re-using your stock grips now is the time to remove them. To remove
the grip take the nozzle that comes with your canned air and ram it in
between the grip and bar, then put your hand over the grip above the
nozzle to trap in the air and as you shoot the air pull like mad to
remove. The other option, which is what I used, is use your air
compressor with a nozzle to shoot air under the grip in the same
manner just described. Like I said, I used my air compressor and it
worked great!:
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Now move to the
throttle side and ONLY LOOSEN these Phillips head screws enough
for the pin to clear the hole in the bar. Once loose work the casing
apart and leave it be for now! Again, if you’re gonna’ re-use the
stock grips just leave it alone. If you’re gonna’ swap grips you can
either remove the grips BEFORE loosening the casing OR swap them out
after the transfer. I swapped my throttle side grip out AFTER the
throttle assembly transfer to the new bars:
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OK, now we’re
ready to remove the old bars. You need to remove the 4 bolts shown
here and numbered one, then just for reference you can see how number
two is ONLY loose. Number two is only loose because after you remove
the bolts and clamp for the handle bars you can simply lift the bars
up and slide the throttle assembly off which IMO makes it easier when
reassembling. There is a pin inside the throttle assembly [casing]
that you need to make sure is out of the bar before yanking on the
assembly to remove. The pin serves as an alignment tool, and the
Sport Bars V2 has a hole drilled for you already:
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So here’s where
we stand. DO NOT, I repeat DO NOT take your bike for a test ride
now. LOL,
J.
You can see the towels I placed on the upper fairings to avoid any
unwanted damage. Oh, and you don’t need to remove the windscreen,
mine is remove because this was one of my mod days and I was fitting
frame sliders and a ZG DB Short screen:
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Now let’s put the
new bars on with the hardware that come with the new bars.
-
First
take the handle bar clamp and
install it, number one in the pic, I used loc-tite blue on all four
of these bolts.
-
Second take the
left side bar and insert it, but DO NOT tighten the ‘’clamp’’ bolts
yet, then get the left [clutch] side back together by properly
installing the casing and clutch.
-
Third work on
right [throttle] side, for the right side I had the best luck
sliding the bar in, then sliding it down and into the throttle
sleeve / assembly, fit the pin from the casing into the hole in the
bar and then assemble the brake lever.
-
Make sure you
take care and line up the “pin” from the throttle and clutch side
housing [casing]. The let [clutch] side is easy, but the right
[throttle] side can be a bit frustrating!
***Use the
directions that came with the Sport Bars V2 to measure and determine
which bar fits which side. Also use the directions that came with the
sport bars to put the bar end bolts together that come with the
bars.*** This sounds like a mouth full and it is, but pics were
minimal as you definitely need two hands to accomplish it. Now once
you have everything adjusted the way you want it you can tighten the
bars up by the bolts noted as 2 and 3 in the pic to the right:
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If you are
swapping grips and you didn’t remove the right [throttle] side now is
the time to take off the old grip using the technique listed above in
the earlier step. If you are putting brand new grips on they are
fairly simple to install. You can use hairspray to lube the new grip
or griplock as pictured below. I used griplock, if your new grips
don’t have holes at the end measure them up and cut a hole in the end,
then take the griplock a squeeze some on the inside of the grip, use
your finger to smooth it around and then slide the grip on the bar and
throttle sleeve. Once the grip is one rotate the grip to where you
want it to be and leave the grip alone for the time specified with
their instructions:
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Now, your mileage
may vary but at a full left turn my brake line was hitting the
instrument cluster housing. I did not want to mark up the housing, so
I flipped the brake line around. To do this you need brake fluid,
brake bleeder bottle and a 10MM open or box end wrench. IF YOU ARE
NOT comfortable bleeding brakes, DO NOT – I REPEAT DO NOT DO THIS,
period end of discussion! I’m not covering brake bleeding, but this
is the brake line and banjo bolt:
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And here’s a
brake bleeder bottle. You can use a single line [see arrow] and bleed
one caliper at a time:
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Or you can use a
double line adapter and bleed both lines at the same time. FWIW, I
find it works best to do one caliper at a time. I think you get a
much tighter feel at the brake lever:
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Ok now you
reassembled everything, put your old or new grips on and put your old
or new bar ends on. Looks good huh! :
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And a closer shot of the bars:
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And a close up of
my new grips with stock bar ends:
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Disclaimer: Not for
distribution, redistribution, sale, re-sale or otherwise without my
written consent. This information is presented with no liability or
guarantee expressed or implied, work at your own risk.
Copyright © Magnum / Magnum1.com 2003-2008. |
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