Sportster 1200: Mini Ape Hanger Handlebars Install Guide

by Alex Braham 57 views

Hey guys! Thinking about giving your Sportster 1200 a cool, custom look and a more comfortable riding position? One of the best ways to do that is by installing mini ape hanger handlebars. These bars not only look awesome, but they can also make a huge difference in how your bike feels on long rides. In this guide, we'll walk you through everything you need to know to get the job done right. Let's dive in!

Why Choose Mini Ape Hangers for Your Sportster 1200?

Before we get into the nitty-gritty of installation, let's talk about why mini ape hangers are such a popular choice for Sportster 1200 owners. There are several benefits that make them a worthwhile upgrade:

  • Enhanced Comfort: One of the primary reasons riders switch to mini apes is the improved comfort. The higher hand position can reduce strain on your back, shoulders, and wrists, especially during longer rides. This more relaxed posture can make a world of difference, allowing you to enjoy your time on the road even more.
  • Custom Look: Let's be honest, mini ape hangers look fantastic. They give your Sportster 1200 a classic, old-school chopper vibe that's hard to beat. Whether you're going for a retro look or just want to stand out from the crowd, these bars will definitely turn heads. With various finishes and styles available, you can find the perfect set to match your bike's overall aesthetic.
  • Improved Control: While it might seem counterintuitive, many riders find that mini apes actually improve their control over the bike. The wider grip and higher leverage can make steering easier, especially at lower speeds. This can be particularly beneficial in urban environments or when navigating tight turns. Plus, the improved posture can give you a better overall feel for the bike.
  • Personalization: Mini ape hangers come in a variety of sizes and styles, allowing you to customize your bike to fit your individual preferences. Whether you prefer a more subtle rise or a taller, more aggressive look, there's a set of mini apes out there that's perfect for you. You can also choose from different finishes, such as chrome, black, or even custom colors, to further personalize your ride. The ability to tailor your handlebars to your specific needs and tastes is a huge part of what makes them such a popular upgrade.

Choosing the right set of mini ape hangers involves considering factors like rise, pullback, and overall width. It's essential to measure your bike and think about what feels most comfortable for you. A good fit will not only enhance your riding experience but also ensure that your bike looks balanced and proportional. With the right mini ape hangers, you can transform your Sportster 1200 into a truly unique and personalized machine. Don't rush the selection process; take the time to explore different options and find the perfect match for your style and riding needs. After all, the handlebars are one of the most important contact points on your bike, so it's worth investing in a set that feels just right.

Tools and Materials You'll Need

Before you start wrenching, make sure you have all the necessary tools and materials on hand. This will make the installation process smoother and prevent any frustrating interruptions. Here’s a comprehensive list:

  • New Mini Ape Hanger Handlebars: Obviously, you'll need a set of mini ape hangers that fit your Sportster 1200. Make sure to check the compatibility and dimensions before purchasing.
  • Socket Set and Wrenches: A good set of sockets and wrenches in various sizes is essential for removing and tightening bolts and nuts. Metric sizes are typically used on Harley-Davidson motorcycles.
  • Torque Wrench: Using a torque wrench is crucial for tightening bolts to the correct specifications. This prevents over-tightening, which can damage components, and under-tightening, which can lead to loosening over time. Consult your bike's service manual for the correct torque values.
  • Allen Wrench Set: Allen wrenches, also known as hex keys, are needed for various fasteners on your handlebars and controls. Make sure you have a complete set in both metric and standard sizes.
  • Wire Strippers and Crimpers: If you need to extend any wiring, wire strippers and crimpers are a must. These tools will allow you to safely and securely connect wires without damaging them. Proper wiring is essential for the safe and reliable operation of your bike.
  • Electrical Tape or Heat Shrink Tubing: Use electrical tape or heat shrink tubing to insulate and protect any exposed wires. This will prevent shorts and ensure that your electrical connections are weatherproof.
  • Wiring Extension Kit (if needed): Depending on the height of your mini ape hangers, you may need to extend your wiring to reach the controls. A wiring extension kit will provide you with the necessary wires, connectors, and instructions.
  • Clutch and Throttle Cable Extensions (if needed): Similarly, you may need to extend your clutch and throttle cables to accommodate the higher handlebars. Make sure to purchase extensions that are compatible with your Sportster 1200.
  • Brake Line Extension (if needed): If your brake line is too short, you'll need to replace it with a longer one. It's crucial to use a brake line that is specifically designed for your bike and meets all safety standards.
  • Grease: Apply grease to the handlebar clamps and control mounts to ensure smooth operation and prevent corrosion. A small amount of grease can make a big difference in the longevity and performance of your components.
  • Threadlocker: Use threadlocker, such as Loctite, on critical fasteners to prevent them from loosening due to vibration. This is especially important for components like handlebar clamps and control mounts.
  • Multimeter: A multimeter can be helpful for testing electrical connections and troubleshooting any wiring issues.
  • Shop Rags: Keep a supply of shop rags on hand to wipe up any spills and keep your work area clean.

Having all these tools and materials ready before you start will make the installation process much more efficient and enjoyable. It also ensures that you can complete the job safely and correctly, without having to make any last-minute trips to the hardware store.

Step-by-Step Installation Guide

Okay, let's get down to the actual installation. Follow these steps carefully to ensure a smooth and safe process:

  1. Preparation:

    • Disconnect the battery: This is the most important first step! Disconnecting the battery prevents any accidental electrical shorts during the installation process. Locate the battery terminals and use a wrench to disconnect the negative terminal first, followed by the positive terminal. Secure the cables away from the terminals to prevent them from accidentally touching and causing a short.
    • Remove the seat: Removing the seat provides better access to the wiring and other components under the seat. This makes it easier to route cables and wires, and it also gives you more room to work. Consult your bike's service manual for instructions on how to remove the seat.
    • Loosen and remove the stock handlebars: Use the appropriate sockets and wrenches to loosen the handlebar clamps. Once the clamps are loose, carefully remove the stock handlebars. Be sure to support the handlebars as you remove them to prevent them from falling and damaging any components. Also, take note of the position of the handlebars and controls before removing them, as this will help you position the new handlebars correctly.

  2. Remove Controls and Grips:

    • Carefully remove the grips: Use compressed air or a specialized grip removal tool to loosen the grips. If the grips are glued on, you may need to use a solvent to dissolve the adhesive. Be careful not to damage the grips during removal, as you may want to reuse them.
    • Detach the switches, levers, and throttle assembly: Use the appropriate Allen wrenches and sockets to detach the switches, levers, and throttle assembly from the stock handlebars. Keep track of all the screws and bolts, and label them if necessary, to ensure that you can reinstall them correctly. Also, take note of the position of each component to make reassembly easier.

  3. Wiring Extension (if needed):

    • Extend the wiring: If your new mini ape hangers require longer wiring, now is the time to extend it. Use wire strippers and crimpers to connect the new wiring to the existing wiring. Be sure to use the correct gauge wire and secure all connections with electrical tape or heat shrink tubing. Follow the instructions provided with your wiring extension kit.
    • Route the wires through the handlebars: Carefully route the extended wires through the new mini ape hangers. Use a wire snake or fish tape to make this process easier. Be sure to protect the wires from sharp edges to prevent damage. Also, leave enough slack in the wires to allow for handlebar movement.

  4. Install New Handlebars:

    • Position the new handlebars: Place the new mini ape hangers in the handlebar clamps and position them to your desired angle. Use a level to ensure that the handlebars are straight. Also, make sure that the handlebars are centered in the clamps.
    • Tighten the handlebar clamps: Use a torque wrench to tighten the handlebar clamps to the manufacturer's specifications. Be sure to tighten the bolts evenly to prevent the handlebars from slipping. Over-tightening the bolts can damage the clamps, while under-tightening can cause the handlebars to loosen over time.

  5. Reinstall Controls and Grips:

    • Reattach the switches, levers, and throttle assembly: Reattach the switches, levers, and throttle assembly to the new mini ape hangers. Use the screws and bolts that you removed earlier. Be sure to position each component correctly and tighten the fasteners to the manufacturer's specifications.
    • Reinstall the grips: Slide the grips onto the new mini ape hangers. If the grips are loose, you may need to use grip glue to secure them. Be sure to allow the glue to dry completely before riding the bike.

  6. Cable and Brake Line Extension (if needed):

    • Replace the clutch and throttle cables: If your new mini ape hangers require longer cables, now is the time to replace them. Disconnect the old cables from the engine and controls, and install the new cables. Be sure to lubricate the cables to ensure smooth operation. Also, adjust the cable tension according to the manufacturer's specifications.
    • Replace the brake line: If your new mini ape hangers require a longer brake line, now is the time to replace it. Disconnect the old brake line from the master cylinder and caliper, and install the new brake line. Be sure to bleed the brakes after replacing the brake line to remove any air bubbles. Also, check for leaks and ensure that the brakes are functioning properly.

  7. Final Adjustments:

    • Check all connections: Double-check all wiring, cable, and brake line connections to ensure that they are secure and properly connected.
    • Test the controls: Test the switches, levers, and throttle to ensure that they are functioning properly. Also, check the brakes to ensure that they are working correctly.
    • Adjust the mirrors: Adjust the mirrors to provide a clear view of the road behind you.

  8. Finishing Up:

    • Reinstall the seat: Reinstall the seat and secure it in place.
    • Reconnect the battery: Reconnect the battery, starting with the positive terminal and then the negative terminal.

Safety First!

  • Always disconnect the battery before working on any electrical components. This prevents accidental shorts and potential injury.
  • Use a torque wrench to tighten bolts to the correct specifications. Over-tightening can damage components, while under-tightening can lead to loosening over time.
  • If you're not comfortable working on your bike, take it to a qualified mechanic. It's better to be safe than sorry.
  • After completing the installation, test ride your bike in a safe area to ensure that everything is working properly. Pay close attention to the handling and braking.

Conclusion

Installing mini ape hangers on your Sportster 1200 is a fantastic way to customize your ride and improve your comfort. By following this guide and taking your time, you can achieve a professional-looking result that will turn heads and make your bike a joy to ride. Remember to prioritize safety and double-check all your work. Now get out there and enjoy the open road with your newly customized Sportster!