Owner guide manual

How to Take the Metal Off Handlebars

Metal handlebars are strong, lightweight bent tubes used on motorcycles for steering the front wheel. Over time the finish on handlebars can become scraped, exposing the bare metal. Exposed metal rusts and oxidizes, eventually reducing the handlebar strength. Rust and oxidation on the handlebars can also spread to other parts on the motorcycle, lowering its value and usability. Removing the damaged metal from a handlebar reduces the chance rust will spread and maintains its structural integrity.

Instructions

1

Slide the handlebar grips off the handlebars. If the grips have a metal attachment screw at the end, remove this first with a screwdriver. Pull the grips the same direction as the handlebar ends, twisting back and forth if necessary to loosen it. On the throttle side of the handlebars, twist only the opposite way of open throttle to loosen the grip.

2

Remove all cable, throttle assembly, mirror and gauge brackets on the handlebars using a screwdriver to loosen the tightening screws. Once loose, pull the brackets off the handlebars by bending the bracket sides apart with pliers. If the bracket is tight, slide it off the handlebars to avoid breaking it. Set each component gently on the front fender or strut of the motorcycle.

3

Unbolt the handlebar attachment brackets using a socket set, which frees the handlebars from the front end fork for removal. Keep the top parts of the brackets and the respective bolts in a plastic bag to avoid losing them. Pull the handlebars off the fork while avoiding any sharp metal edges.

4

Remove the finish, rust and oxidation from the handlebars using a bench grinder fitted with a soft wire wheel. This process is known as deburring and is performed by brushing the handlebars lengthwise on the grinder the same way the wheel is spinning. Spin the handlebars often while deburring to ensure all the finish and defects are removed.

5

Sand the handlebars using 800 or higher grit sandpaper to remove any scoring caused by the wire wheel and creates a paintable surface on the handlebars.

6

Prime the handlebars with a bare metal primer designed to stop rust. Allow to dry at least 12 hours, then apply the finishing paint of choice and allow to dry another 12 hours. Apply semi-gloss to the handlebars, if desired, to produce a shiny finish.

7

Wait 24 hours after applying semi-gloss. Reinstall the handlebars on the forks using the socket set and brackets.

8

Install mirror, throttle, cable and gauge components and respective brackets. Slide the handlebar grips back on to complete the handlebar metal removal.