2004 Harley Davidson Sportster Install an Ape Hangers
The type and position of the handlebars on your motorcycle determine your upper body comfort while riding -- especially for long periods. Ape hanger handlebars are taller than stock handlebars, allowing you to stretch your upper body out while riding. You must choose the height that matches your comfort level by sitting on your motorcycle and holding different sets of handlebars in the appropriate position to determine the best height for you. Ape hanger handlebars are an inexpensive upgrade to your Sportster.
Install an Ape Hangers
- Remove the maxi-fuse -- located in the fuse holder on the battery strap -- by hand to cut all power to the motorcycle.
- Remove the two screws that connect the clutch assembly to the left-hand side of the handlebars with a screwdriver. Also with the screwdriver remove the two screws that connect the left handlebar switch assembly to the handlebars. Remove both the left and right handlebar grips by pulling them outward by hand. Also remove the front master cylinder assembly from the left-hand side of the handlebars with a screwdriver. Remove the two screws -- with a screwdriver -- that hold the throttle assembly in place on the right-hand side of the handlebars.
- Remove, by hand, the retainers that connect the cables to the handlebars. Loosen the screws connecting the control housing to the handlebars. Do not remove the screws completely. To remove the lower handlebar clamps that connect the handlebars to the fork bracket, loosen the two bolts that connect them. Remove the screws and washers that connect the upper handlebar clamp in place with a screwdriver. Remove the two screws that hold the instrument bracket in place. Remove the handlebars from the motorcycle.
- Attach new ape hanger handlebars to the motorcycle. Reconnect the bolts that connect the handlebars to the fork bracket. Tighten by hand. Tighten the screws of the throttle assembly with a screwdriver. Reattach the upper handlebar clamp and washers. Tighten the screws with a screwdriver. Reattach the instrument bracket and the two screws that hold it in place.
- Move the handlebars to the position most comfortable for you while you sit on the motorcycle. Once you determine the appropriate position for the handlebars, tighten the screws of the upper handlebar clamp and instrument bracket to 12 to 18 foot-pounds with a torque wrench until the upper handlebar clamp touches the lower handlebar clamps. Tighten the lower handlebar clamp bolts to 30 to 40 foot-pounds with a torque wrench.
- Slide the throttle cable assembly back in place on the right-hand side of the handlebars. Reattach the front master cylinder to the left-hand side of the handlebars and tighten the screws that connect it with a screwdriver. Reattach both the left and the right-hand grips by pushing them back in place. Reattach the left-hand switch assembly and the clutch assembly and tighten the screws that hold each of them in place. Reinstall the maxi-fuse.