A “HOW TO GUIDE” for changing handlebars and risers or upgrading front brake lines. 

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STEP 1

REMOVAL OF HANDLE BARS

First you need to remove the cables. This is a stock XV950 abs. the racer is different but the principle is the same.

The electrical cables should have enough play to ease them out.

the same process on the right side

You can now access the bolts that hold on the speedo mount. remove bolts from both sides.

 You have access now to the riser bolts for later

You don’t need to cut the cable ties.. put a screwdriver in the lock and you can slide them out. release all the cables.

Now to remove the clutch cable. Loosen the clutch cable tension. rotate all the way in.

Line up the slots

Now you can ease the cable through.

Pull the cable end down to release it.

next up are the throtlle cables. can be removed from the bar end or throttle body. We are changing the cables so we will do the throttle body end first. 

loosen the throttle cable tension. this will make the next step easier.

 loosen the cable nuts to remove the cable from the cam.

this is the cable end you need to release.

cable end released

second cable end released.

next up are the electrical cables. disconnect right side electrical connection.

these are the left side electrical connections. they are mounted on a metal plate.

use a screwdriver to ease out the clip.

push the screwdriver down to release the clip.

seperate the connector 1. this is the clip you need to release.

seperate connector 2. this is the slot you need to put the screwdriver into.

remove the headlight mount to create room for cables to pass.

right side mount bolt to be removed. Wera tools fit perfect!!

you need to release the cables from all the cable guides

more cable guides. just ease out cables where required

check left side electrical connections are clear

check right side electrics are clear and throttle cables can pass through the triple tree. pull clutch cable through the tree. no need to disconnect clutch at the engine end.

remove the brake banjo bolt. have plenty of paper towels ready or a pot to catch the fluid. dont spill dot 4 on your paint. if you do clean immediately. cover the brake line with tape and tape in place to prevent drips. dont pull the brake lever.

now you can release the riser bolts and remove the bars.

have a bench prepared for you to put your bars.. dont empty the brake reservoir until you are ready to install. just cover the hole to control the drips. next step is to prepare for the new risers..

you have completed thos section.. well done if you made it here..

see part 1 (tank removal) here  https://mbcustoms.eu/2021/02/02/handlebar-extension/(opens in a new tab)

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