How do you change the handle bars on a 02 sportster xlh1200?

Answer 1

Changing the handlebars can be very straightforward, if you make sure of a few things first. 1) Is the new bar taller or shorter than the existing bar? While clever routing of the clutch and throttle cables can be done for taller or shorter bars, the brake line can be more of a problem. 2) The diameter of the handlebar should be the same as the old bar. If it isn't, your grips, controls, and riser clamps will not fit. 3) You MUST MUST MUST make sure that the bar has knurling at the point of attachment. Those little crosshatched grooves are there to keep the bar from flopping over in a panic stop. Once you've gotten all of the above bases covered, it's time to begin. Cover your tank with some towels to protect from tool impacts. Remove the controls and cables, if you need to. Take off the top riser clamp, and the bar will come free. Just reverse the operation and you should be done. Note though, that if your current bar has a stock rubber grip, it will be VERY difficult to remove it without cutting it free, and thus destroying it. This might be the time to invest in some new grips, too.