If you're wondering how to replace Harley handlebars, there’s good news. Swapping out handlebars on your Harley-Davidson can dramatically change your riding experience, comfort, and style. 

Whether you want a new look, improved ergonomics, or better control, replacing the handlebars is one of the most impactful upgrades you can make to your motorcycle. Even though the process may seem confusing at first, it’s manageable with the right tools, patience, and step-by-step guidance.

Why Replace Harley Handlebars?

Handlebars are a huge part of your motorcycle’s setup. They influence your posture, steering feel, and overall control of the bike. Over time, you might find that your current handlebars don’t suit your riding style anymore, or maybe you want to upgrade to something more custom, like ape hangers or drag bars. 

Upgrading handlebars can also allow you to install new motorcycle accessories like custom grips, mirrors, or switch housings.

Swapping out handlebars is not just about aesthetics. It’s about adapting your bike to your personal needs. A proper handlebar choice reduces rider fatigue and can improve your safety by putting controls in a better position. 

You might also want to match your new bars with compatible bags and packs or other accessories, so everything works together.

Tools and Preparation

Before getting too involved in the actual replacement, gather the right tools. You’ll usually need a set of Allen wrenches, screwdrivers, socket wrenches, and possibly torque wrenches for bolts that require specific tightness. 

Have some cleaning supplies on hand to wipe down any parts during the swap. It’s also smart to have a service manual specific to your Harley model, as some handlebar setups differ slightly.

Disconnect the battery before starting to avoid accidental electrical issues when working around handlebar switches. Removing handlebars involves detaching the grips, cables, wiring, and switches, so a methodical approach reduces mistakes.

Removing the Old Handlebars

Begin by loosening the clamps that secure the handlebars to the triple tree. On many Harley models, this involves removing the faceplate bolts on the handlebar clamp. Carefully lift the handlebars free but take care to support all attached cables and wiring to avoid damage.

Next, remove the hand grips. If you need to know how to replace Harley hand grips later, this is the first step. Grips can be stubborn, using a bit of rubbing alcohol or compressed air can help slide them off without tearing.

Then disconnect the handlebar switches. These are usually held by screws or clips, and wiring harnesses plug into connectors. Note the positions of wires and switches, or better yet, take pictures to help with reassembly. 

If you plan to change or upgrade your handlebar switches, this is your moment to remove the old ones carefully.

Preparing the New Handlebars

Before installing, inspect your new handlebars for any shipping damage or manufacturing defects. Clean the bars and remove any protective coatings. If your new bars have holes for wiring, make sure they line up with your bike’s cables and switch housings.

Depending on the style of your new handlebars, you might need to reroute cables or extend wiring. Some riders take this opportunity to upgrade to higher-quality cables or custom grips. 

If you plan to mount motorcycle accessories like mirrors or handlebar bags, verify their mounting points and clearance with the new bars.

Installing the New Handlebars

Set the new handlebars into place on the triple tree. Align them straight with the front wheel for proper steering geometry. Tighten the clamps just enough to hold the bars securely but still allow slight movement for adjustment.

Route cables and wires carefully along the bars. Avoid sharp bends or pinching points to prevent wear or electrical problems. Attach your grips next. If you need to, consider applying a small amount of grip glue or using compressed air to slide them on evenly.

Reinstall the handlebar switches and reconnect all wiring connectors as noted during removal. Test all switch functions like turn signals, horn, and lights before fully tightening clamps to avoid needing to loosen them again.

Adjusting for Comfort and Control

Once everything is mounted, sit on your bike to check the feel of the new handlebars. Your arms should reach the grips without overextending, and your wrists should feel natural when resting on the bars. Adjust the angle and position slightly by loosening the clamps again and rotating the bars if necessary.

Tighten all bolts to the recommended torque settings to keep everything secure. Loose handlebars are a safety hazard, so double-check your work.

Tips for a Clean Install

Replacing handlebars offers a chance to clean and maintain related parts. Wipe down the cables and connectors. Inspect your throttle cables for wear or kinks and replace them if needed. Consider swapping out old grips for fresh ones that improve your hold and feel.

If you carry bags and packs, verify that your new handlebars don’t interfere with mounting points. Some tall or wide bars may require relocating or adjusting storage options. For long rides, balance between style and functionality is important to keep your gear accessible.

How to Replace Harley Handlebar Switches

If you’re changing switches along with the bars, disconnect all wiring connectors gently. Old switches may have screws holding them in place or be clipped on. 

After removing the old switch, install the new one by reversing the steps and connecting wires properly. It’s helpful to label each wire or take detailed photos before disconnecting to avoid confusion during reassembly.

Make sure the switches fit the style and diameter of your new handlebars. Some aftermarket switch kits are universal, while others are designed for specific Harley models or handlebar sizes. 

When choosing new switches, consider compatibility not only with the bars but also with your bike’s electrical system. Some switches may require minor rewiring or additional connectors.

After installation, check the operation of every button and switch to confirm smooth function before riding. Test signals, horn, headlights, and kill switches to verify electrical continuity and proper responsiveness. Loose connections or mis-wired switches can cause malfunction and pose safety risks on the road.

If your new handlebars have a different diameter or contour than the originals, the switch housings might not fit perfectly. In such cases, modifying the housings or using flexible mounting brackets can solve the problem. Some riders also upgrade to waterproof or sealed switches for better durability.

Common Challenges and How to Overcome Them

One common obstacle is cable length. After changing to taller or wider handlebars, factory cables might be too short or tight. In this case, ordering longer cables or cable extensions is necessary to prevent strain or failure. Avoid forcing cables, as this can lead to premature wear or snapping while riding.

Electrical connectors can also be tricky if the wires are short or routed differently. Using zip ties and protective sleeves can help secure wiring neatly along the bars, preventing chafing or pinching. Taking your time in this step prevents future electrical problems caused by loose or damaged wiring.

Another challenge is matching the new handlebar style with your existing motorcycle accessories. For instance, some windshield mounts or bags might not fit the altered bar shape or position. 

Be prepared to adjust accessory placement or invest in compatible parts. Testing the fit of your gear before finalizing the handlebar installation can save headaches later.

Why Handlebar Replacement Matters

Changing your handlebars transforms the riding position and handling feel. It can reduce fatigue, improve control, and customize your motorcycle’s personality. By learning how to replace Harley handlebars, you unlock an important customization that many riders overlook.

This task also deepens your connection to your bike. Hands-on work creates appreciation for the mechanics behind your ride. 

Even if you’re not a professional mechanic, following detailed instructions and taking your time will result in a successful upgrade. The process builds confidence in maintaining and modifying other components of your motorcycle.

Final Checks Before Hitting the Road

Before your first ride with new handlebars, do a thorough safety check. Confirm all bolts are tight, switches respond properly, and cables move freely without binding. Test the throttle and clutch action to help guarantee smooth operation. Adjust mirrors and check your visibility from the riding position.

A short test ride around your garage or driveway can reveal any uncomfortable positions or control issues. If you notice anything unusual, address it immediately.

This process assures that your motorcycle accessories and controls all function harmoniously and your bike feels balanced and comfortable. Taking the time to finalize these details contributes to safer, more enjoyable rides ahead.

Mototeks: Your Partner for Harley Customization

Mototeks knows the thrill of customizing your Harley-Davidson. Our selection of motorcycle accessories and parts is designed to support your projects, whether you’re replacing handlebars, upgrading grips, or adding storage solutions like bags and packs.

We pride ourselves on offering quality aftermarket components that fit a range of Harley models. Our goal is to help riders create bikes that feel like an extension of themselves. From the smallest detail to major modifications, we’re here to help you get it done right.

Ordering from us means access to worldwide shipping and affordable pricing, so riders everywhere can improve their bikes without hassle. If you want to learn more about how to replace Harley handlebars or need parts for your build, our team is ready to assist. Contact Mototeks for any questions or advice about your Harley customization.