Tightening handlebars wont be something that you do very often as once they are installed that is generally it. They shouldn’t be moving about and causing any concern unless they haven’t been tightened properly in the first place or you are replacing them. The only other reason maybe, like me with my XR250, you are stripping it down and rebuilding it. Fun Times!
With your handlebars placed on the clamps, start by tightening the 4 clamp screws by hand. As the screws start to tighten make sure the handlebars are in your prefered position by pushing them forward or pulling them backwards. When in position tighten the clamp screws with the relevant tool ( likely an allen key). Be sure to tighten them up equally so you have an equal gap between the front or back of the clamp and the base of the clamp. Finish with a torque wrench and tighten to the spec in your manual.
Adjusting Your HandleBars
This is another easy thing to do. Simply loosen the clamps bolts with your allen key, without taking them out, just enough so the handlebars will move.
I like to straddle the bike and do it from the rider position, but you can do it stood next to it. You will either be pushing the bars towards the front fender or pulling it backwards towards the rear fender to get your preferred postion.
Once you are the bars are where you want them tighten the bolts back up, making sure to do it evenly so there is an even gap between the top and bottom part of the clamps.
How To Cut Down Handle Bars For Your Dirt Bike
Thought I would quickly talk about cutting down your handle bars because it is quiet common, especially among woodland rider who like to have them a little narrower to avoid them hitting trees and foliage.
The best way I have found to cut down handle bars is to use a pipe cutter, the tool plumbers use to cut copper piping. Here’s the one I used which you can get off Amazon – check Amazon prices here
If you use a brandnew one then you might cut lucky and it may cut through the entire bar. However it will depend on bar thickness as some bars , like pro-tapers for example maybe to thick.
What ever the thickness of the bars the pipe cutter is still worth using because it will give you a nice square cut.
So, some bars will have measurement lines already on the bars to tell you where to cut. If not then decide on the amount you want cutting and use a measure to mark the bars.
Once marked, use the pipe cutter to start the cut and finish if possible. If the cutting wheel isnt big enough to go deep enough into the bars to cut it completely then you will need to finish of with a hacksaw.
After cutting I like to run some sandpaper around the cut to soften the edge and make sure it wont slice my finger.
That’s it you should be good to go.