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Discussion Starter #1
Im looking to swap my stock bars with some buckhorns i recieved. Was wondering if anybody could lend some guidance towards the process. Mainly if ill need to get some custom cables and such. If i should drill the control holes or grind off the tabs. Anything would be helpful
 

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For bars like that, I'm sure you'll need new cables. The stock lines can work with lower bars or slightly higher but any more than that, there won't be enough line. I tried out a set of flipped clubmans a little while back that were only 4.5" high/27.5"wide and even for those the front brake line just barely worked and the cables were a bit tighter than I would've liked.

As far as the tabs, I would drill the holes. I won't preach one way or the other because on my scooter I just grinded the tabs off and they hold well, but I'm not going 60+ mph on a scooter so I am not as worried about it. I would spend the extra time to measure and drill out the holes for piece of mind.
 

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Discussion Starter #4
Yea i was afraid id have to go down that road. Finally after a lot of calls and searching I found a company who can make them for me and have the oe specs to go off of. Guess now i just need to put the new bars on and measure out how much extra i will need and have them made
 

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How much did they quote you for new cables and lines? I was going to put new bars on but didn't want to go down that road as I thought it would be pretty expensive.


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Discussion Starter #6
clutch cable $60 a piece. Throttle cables about $53 a piece. They would want you to disconnect your old bars and controls and mount the new bars and figure out the extra length needed. I think im going to hold off on it and just do some other things to change up the front end appearance instead. Too close to riding season and i dont want to lose any time with a project like that.
 

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I think I've posted elsewhere on this forum that when I replaced the handlebars on my girlfriend's 500, the front brake line wasn't long enough. I ordered a custom line and manifold from Spiegler and after shipping I paid $100. Replacing the brake line isn't trivial because the stock line and manifold are one piece and the manifold is attached under the tank behind the black plastic covers. For anyone who hasn't had the opportunity to do this yet, you're in for a real treat after you remove the gas tank. All the electronics under the tank have to be removed and it's a rats nest under there. It's hard enough to take it all apart, but putting it back together is even a bigger challenge and you better hope you've taken lots of pictures as reference for how things go back together. It's the most challenging work I've done on the motorcycle so far.
 

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Discussion Starter #11
Well i got engine crash bars for sale if anyones interested. Say they are for the 300 but they could work on the 500 from what i can tell with trying them up to my bike.
 

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Discussion Starter #17
The way they mount are set up for the 300. The dual pipe exhaust up front on the 500 is a factor along with not having a plate down below the radiator like the 300 does to mount to. The way to properly mount them is on the 300 because it has different mounting points than the 500. I could make it work on my 500 but I figured id help somebody out with a 300 that has wanted these but dont want to wait 2 month shipping from thailand.
 

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I did 7” biltwell bars all cable fit just redirected them
Can you link the handle bars? This is their exact look I want to go for. And you mentioned that you only had to route the clutch cable, how hard was that?
https://m.ebay.com/itm/Biltwell-Breezer-bars-ape-Z-Handlebar-motorcycle-Harley-1-Black-non-dimpled/380852249763?hash=item58ac9024a3:g:AKYAAOxyYSdTDXPR

Biltwell breezer bars they are discontinued now from biltwell but eBay has some still. Routing the clutch cable under tank roughly 30-45 minutes. Only lifted tank high enough to run the cable. I did not disconnect any wires or fuel lines. It had the spots for the preset notches which worked out great. 8” bars with 6.25 drop.
Brake line was only disconnected from the mid point on the forks and zipped tied upped.
Throttle and return was also moved
 

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I did 7” biltwell bars all cable fit just redirected them
Can you link the handle bars? This is their exact look I want to go for. And you mentioned that you only had to route the clutch cable, how hard was that?

https://m.ebay.com/itm/Biltwell-Breezer-bars-ape-Z-Handlebar-motorcycle-Harley-1-Black-non-dimpled/380852249763?hash=item58ac9024a3:g:AKYAAOxyYSdTDXPR

Biltwell breezer bars they are discontinued now from biltwell but eBay has some still. Routing the clutch cable under tank roughly 30-45 minutes. Only lifted tank high enough to run the cable. I did not disconnect any wires or fuel lines. It had the spots for the preset notches which worked out great. 8” bars with 6.25 drop.
Brake line was only disconnected from the mid point on the forks and zipped tied upped.
Throttle and return was also moved
Thanks so much man!
 
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