How to Install 7/8 Inch and 1 1/8 Inch Handlebars

Updated: 11/30/2020

Note: This guide is suitable for those wishing to install aftermarket handlebars on the Triumph Street Twin, Street Scrambler, and Bonneville Speed Twin. 

Thank you for choosing British Customs. These British Customs products have been designed and tested to fit multiple Triumph Motorcycles based on the diameter of the installed handlebar. Clamps are available in three diameters to accommodate multiple applications.  

The following installation is performed on a 2019 Triumph Speed Twin using the Retro Bar Kit for Speed Twin. This kit includes a 7/8 Inch Handlebar and Clamps. The steps for an oversized bar are the same.

Completely read all these instructions before installing the British Customs product to become thoroughly familiar with the features and the installation process.     

STEP BY STEP GUIDE

1. Remove the Handlebars (See How to Remove Handlebars)

2. Remove the Brake Line *If New Brake Included (See How to Remove ABS Brake Line  - Liquid Cooled)

3. Install new ABS Brake Line *If New Brake Line Included (See How to Install BC ABS Brake LIne - Liquid Cooled)

4. Remove the Handlebar Clamps *If Four Bolt Clamps Purchased

5. Install BC Four Bolt Handlebar Clamps *If Four Bolt Clamps Purchased (see Install Four Bolt Handlebar Clamps)..

6. Install  Handlebar.  Slide the throttle assembly onto the end of the bar and tighten the handlebar clamp tops using a 6mm Allen.  Tighten the (2) forward bolts until they bottom out.  Then tighten the (2) rear bolts to and torque to 26 Nm.

7. Set the Throttle Assembly and Right Hand Switch Housing to the desired position. Note that the Switch Housing and Throttle Assembly line up.

Note: The Throttle Assembly and Right Hand Switch Housing are pinned and index into the handlebar to prevent twisting during operation. The handlebar has to be drilled to accommodate the pins.  

TIP: If using bar-end mirrors, position the Throttle Assembly .5 inch from the end of the handlebar.

8. Remove the right-hand Switch from the handlebar and mark where the Throttle Housing Pin position. 

9.  Using a Phillips Screw Driver remove the (2) bolts that secure the Throttle Assembly and mark the handlebar.  

Pro Tip:  Use a paint pen or nail polish to mark the pin and press assemble the throttle housing to mark the bar.   

 

10. Using a 7/32 drill bit, drill the handlebar.  The drill location was marked in Step 6.  

Pro Tip:  Use a Center Punch to mark the hole prior to drilling to prevent the drill from wandering

11.  Using a Phillips Screw Driver tighten the (2) bolts that secure the Throttle Housing

12. Line up the Switch Housing with the Throttle Assembly.

13. Mark the handlebar for the Switch Housing Pin is suppose to go.  

Pro Tip: Use a paint pen or nail polish to mark the pin and press assemble the Switch Assembly to to mark the handlebar.

14.  Loosen the throttle assembly and slide towards the end of the handlebar and drill the handlebar. 

Pro Tip Use a Center Punch to mark the hole prior to drilling to prevent the drill from wandering. 

15. Reposition the Throttle Assembly.  Using a Phillips screwdriver, tighten the (2) bolts the secure the Throttle Housing.  

16.  Install the Switch Housing. Using a Phillips screwdriver, tighten the (2) bolts that secure the right-hand switch housing.

 

17. Install the Brake Perch.  Using a 5mm Allen tighten the (2) bolts that secure the Brake Perch. Tighten to 12 Nm

18. Position the left-hand Switch Housing to the desired position.  Mark the handlebar 

Pro Tip Use a paint pen or nail polish to mark the pin and press assemble the Switch Assembly to mark the handlebar.

 

19.  Using a 7/32 Drill Bit drill the handlebar.  

Pro Tip: Use a Center Punch to mark the hole prior to drilling to prevent the drill from wandering.  

20. Install the left-hand Switch Housing. Using a Phillips Screw Driver, tighten the (2) bolts that secure the left-hand switch housing.  

21.  Install the Clutch Perch.  Using a 5mm Allen tighten the (2) bolts that secure the clutch perch and tighten to 8 Nm.  

22. Install new Clutch Cable *If Kit includes a clutch cable.  

Preform a safety check, verify the handlebars, Clutch Perch and Brake Perch are mounted securely. If any of the components can be moved by hand. Re-torque the clamps that secure them the the handlebar. Verify that cables to not bind when the handlebars are turned all the way to the left and right.