GS500 Handlebar Replacement

This documents installing new BikeMaster Daytona Bars and Progrip 723 Gel grips on my 2007 Suzuki GS500.
Tools Used:

• Philips screwdriver
• flathead screwdriver
• 8mm socket wrench
• 6mm hex wrench
• 13/64” metal drill bit and drill
• hammer and center punch
• measuring tape
• side cutters 
• box cutter 
• carb cleaner
• grip adhesive or hair spray
• blanket
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The new bars over the old bars:
 
1) Put the bike on the center stand and put a blanket over the tank to protect it from scratches and the carb cleaner.

2) Remove the bar ends with a Philips screwdriver. By loosening the screw slightly and wiggling the bar end out. Don't loosen the screw all the way or the nut on the inside will fall off inside the bar.
 
3) If you want to reuse your grips, shoot a small amount of carb cleaner under them. This will break up the adhesive holding them on and makes it very easy to slide the grips off the bars. You can also use the razor to slit them down the side. Slide the grips off.

4) Disconnect the two small cables on both the brake housing and the clutch housing.
 
5) Remove the two black screws holding on both switch housings with the Philips screwdriver. Remove the switch housings from the bars.
    
6) Slide the throttle tube off the bars

7) Using the 8mm socket and wrench loosen the bolt holding the lever mounts/mirrors, and remove them from the bars.
  
8) Pry the little caps off of the handlebar clamps with a thin screwdriver.

9) Remove the hex bolts with the 6mm wrench and remove the bar clamps.

10) Remove the bars from the bike

11) Put the new bars into the clamps and tighten slightly. Measure each side of the bars to make sure they are even. I had each side at 13.25 inches.

12) With the 13/64” drill bit, drill a hole about 6.5 inches from each end of the bar. The hole will be the top of the switch housing, so locate in a comfortable position. Using the hammer and punch to make a small dent in the bars before drilling makes them easier to drill as the bit is less likely to wander.
    
13) Put the lever perches/mirror mounts back onto the bars.

14) Put the switch housings back on the bars. The hole in the bars matches up with the bump on the top, inside of the housing.

15) Put the throttle tube back on the bars

16) Pry the end cap from the bars to make room for the bar ends.

17) The new Progrip gel grips. The larger diameter hole is the throttle side.
 
18) Cut the end off the grips to make room for the bar end weights with the side cutter or razor blade.

19) Put the grips onto the bike with some grip adhesive or hair spray. Both will make the grips easy to slide on and hold them in place.
20) Put the bar end weights back on the bike
21) Adjust the bars and levers to the desired angles and tighten everything up.
22) Go for a test ride!

Before:

After:

New (top) and Old (bottom) bars together:

 

 

Written by Chrisluhman for Everyday Riding. All rights reserved.