Cars & Vehicles Auto Parts & Maintenance & Repairs

How to Change Out the Handlebars on the Yamaha V-Star 650 Custom

    • 1). Remove the plastic cable ties from the handlebars to free the switch assemblies' wiring. Unscrew the bolts from the bottom of the left switch assembly with a Phillips screwdriver. Pull the switch assembly apart and remove it from the handlebar. Drape the left switch assembly over the headlight.

    • 2). Loosen the round lock nut on the clutch cable's adjuster, positioned behind the clutch lever on the left handlebar. Turn the cable adjuster clockwise to loosen the cable completely. Pull the clutch cable out of the lever and drape it over the headlight.

    • 3). Cut the left hand grip lengthwise with a razor, then peel the grip off the handlebar.

      Loosen the clutch lever perch's mounting bolt with a 10 mm socket and a socket wrench. Pull the clutch lever perch off of the handlebar.

    • 4). Unscrew the front brake master cylinder's mounting bolts from the right handlebar. Pull the master cylinder away from the handlebar and unplug the wiring from brake light switch.

    • 5). Turn the cable adjusters on both throttle cables, positioned just below the right switch assembly, clockwise to loosen the cables completely. Pull the top of the switch assembly off the handlebar to access the throttle grip and cables. Pull the throttle cables out of throttle grip, then slide the grip off of the handlebar. Pull the switch assembly and the throttle cables off the handlebar.

    • 6). Pull the plastic bolt covers off the handlebar risers on the front fork. Unscrew the risers' bolts with a 5 mm Allen wrench and remove the handlebar. Place the new handlebar onto the risers and tighten the rider bolts with a 5 mm Allen wrench. Push the bolt covers into place to hide the riser bolts.

    • 7). Place a small amount of modeling clay onto the handlebars. Loosely mount the switch assemblies onto the handlebars and press the pins on the bottom half of the switch assemblies into the modeling clay. Remove the switch assemblies and drill a 1/8 inch hole into the handlebar with an electric drill, using the mark left in the modeling clay as a guide.

    • 8). Reinstall both switch assemblies, the front brake master cylinder, clutch lever perch and throttle tube, following the reverse method of removal. Slide a new hand grip onto the left handlebar.

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