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post #1 of 36 (permalink) Old 12-22-2010, 06:02 PM Thread Starter
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Well I got my 2 inch + inch handlebars (powder coated black) a few minutes ago. Already have the bike fairly taken apart. So Now (weather permitting) I can get it back together. All the stuff I have ordered is here.
Handle bars from Santa Rosa, IPod/connection cable and extension, speakers. This will have to do it until after Christmas.
I seen a blacked out XC that looked great. So I am thinking about doing a Blue/black XC. I have found a powder coater that does custom coating. Heat shields and the chrome engine covers.

Merry Christmas

dd
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post #2 of 36 (permalink) Old 12-22-2010, 06:45 PM
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DD, I have the same bars ordered, how much of a hassle is it to change them? I was thinking of letting the dealer do it, but would rather do it muself if not too complex.

The black out idea sounds great!

Please post results as soon as you get them on.

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2007 Harley Dyna
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post #3 of 36 (permalink) Old 12-22-2010, 08:41 PM Thread Starter
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I just got them today and had to teach at church so it will be tomorrow.
I read the service manual on how to change them. It will just be time consuming. Removal if the inner fairing will not be that hard, just 4 bolts and disconnecting a few wire plugs.
If you do decide to do it yourself get everything ready to come off the bars (clutch side grip, and hand controls) before trying to removing the bars.
I will be doing everything at once, handlebars and IPod. So I will be removing the tank.
If you do not have a manual get it here for download
http://redbookhouse.com/manuals/Vict...oss%20Country/
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post #4 of 36 (permalink) Old 12-23-2010, 09:36 AM
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Thanks DD. Please let us know if it takes any special tools, or is particularly challenging. Also, as I understand it, all the stock cables etc are supposed to fit with undo stretching. Hopefully that ends up being the case.

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2007 Harley Dyna
1976 BMW R75/5
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post #5 of 36 (permalink) Old 12-23-2010, 01:30 PM Thread Starter
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I have gotten started on replacing the bars. I decided I would take photos as I go. Maybe it will help someone later.

dd
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post #6 of 36 (permalink) Old 12-23-2010, 01:57 PM
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Originally Posted by dirtdobber View Post
I have gotten started on replacing the bars. I decided I would take photos as I go. Maybe it will help someone later.

dd
I know I am being silly but cover your gas tank really good use a heavy blanket. Go slow and be careful.
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post #7 of 36 (permalink) Old 12-23-2010, 02:52 PM
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I have gotten started on replacing the bars. I decided I would take photos as I go. Maybe it will help someone later.

dd
Great idea! I would like to change mine myself. I presume you have to take the fairing completely off?

Multiple Bike Disorder:crzy:
2011 Cross Country:D
2006 Suzuki Burgman 650
2007 Harley Dyna
1976 BMW R75/5
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post #8 of 36 (permalink) Old 12-23-2010, 05:09 PM Thread Starter
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First off the outer fairing has to be removed but the inner fairing only has to be take lose from the mount so it will move forward to clear the handle bar mounts. You may need to play with it some if you are using lower wind deflectors. The get in the way some. I was able to move it around enough for the inner to clear.

This how I save time, I do not remove anything until it is time and do not take anything apart that doesn't need to. In this photo you can see how I slid the mirror mount out of the way to work. If you are going to use the black powder coated bars take extra caution, you can scratch the bars easily.


When you start to remove the clutch side grip I use a small allen wrench that is round on the end so I will not puncture the grip. I then spray with WD40 thoroughly working the allen farther in as to get the WD40 around every part of the grip then work it until it turns lose.
This photo is the throttle side but you can see how to remove the weighted end by using wood as not to damage the chrome. Give good licks with the hammer them suckers are in there good.


In the lower part of the photo you will see 2 bolts on the fairing mount. There are 4, 2 at the bottom and 2 upward which are hid by the wiring but easily seen. Remove all 4. There are rubber washers with spacers that may come out at the same time if they do set them aside with the bolts, you do not want to lose these guys.



IN this photo you can see the handle bar mounts are exposed. You can put slight pressure on the windscreen (cover it for protection) and you can get to the allen screws on top and the bottom are easy to get to. These suckers are tight so make sure you have the allen all the way in before trying to loosen them.



In this photo you how you need to turn the bars backward to slid the clutch lever mount complete and the throttle housing complete. Normally it is not necessary to flip the bars but due to the length it is. When you flip the bars flip them upward mounting surface, upward.



This last photo is what the black powder coated bars looks like.


If you will be using the black powder coated bars it may be necessary to sand off the coating where the throttle will be. Mine was sticking so I had to remove some of the coating to free it up.

I had to cut the throttle cables ties to get enough slack for them not to be too tight. I had to stop before getting completely finished.
It isn't hard just time consuming.
Momma said to come in so I came in. Ya here me

Hope this helps someone down the road.

Last edited by dirtdobber; 12-23-2010 at 05:14 PM.
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post #9 of 36 (permalink) Old 12-23-2010, 05:17 PM
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DD, VERY helpful, thanks.

One question, when you say you cut the throttle cable, what does this mean? Do these bikes have the "throttle by wire" set up? Not sure I understand it, but the newer Harleys have it.

I see you have a WIng? I have one with a Hannigan sidecar....great machine.

Multiple Bike Disorder:crzy:
2011 Cross Country:D
2006 Suzuki Burgman 650
2007 Harley Dyna
1976 BMW R75/5
1971 BSA Lightning
1947 Harley 45
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post #10 of 36 (permalink) Old 12-23-2010, 05:41 PM Thread Starter
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I had to cut the throttle cables ties to get enough slack for them not to be too tight.
Just under the frame there is a plastic wire tie. I had to cut it so the cable could be moved.
When I posted it see what I had wrote and changed it.

dd
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