How to Change the Handlebars on a Kawasaki Vulcan 1500 Classic

The Kawasaki 1500 Vulcan is known as one of the most comfortable, powerful and easy-to-ride big-engine motorcycles on the market. Its comfortable seating position is in part due to the high-rise handlebars that come stock on the bike. However, if these bars are too high for smaller riders, they may need to be replaced by some with a lower rise. This is a relatively simple procedure that can be done by anyone with a basic tool kit and a place to work.

Things You'll Need

  • 6 mm hex wrench
  • 5 mm hex wrench
  • Phillips head screwdriver
  • 8 mm socket
  • New handlebars
  • Socket wrench
  • Set your Vulcan on its side stand on a level surface. Remove the bar-end cap from both sides of the handlebar using a 5mm hex wrench. Set the caps aside.

  • Twist the left handlebar grip forcefully to loosen the grip adhesive underneath. Pull the grip off the handlebar. If the grip is too difficult to remove, spray a small amount of WD-40 underneath it to loosen it enough to pull if off the bar.

  • Remove the two screws on the back of the plastic control housings on each side of the handlebar and slide both housings off the bars. You can let these hang from the bars without damaging them.

  • Loosen the two 8 mm bolts on each handlebar lever clamp (the brake and clutch levers) using a socket and wrench, then slide the brake lever and clutch lever off the bars. Let them hang from the bike in the same fashion as the control housings.

  • Remove the four handlebar mount bolts using a 6 mm hex wrench. The handlebars will fall free of the bike. Set the new handlebars in their place and reinstall the handlebar mount bolts to secure them to the handlebar mounts.

  • Slide the clutch lever onto the left-side handlebar and the brake lever onto the right-side handlebar. Then slide the left control housing onto the left handlebar and the right control housing and throttle grip onto the right-side handlebar. Using a 5 mm hex wrench, attach the handlebar end caps to both sides of the handlebar.

  • Sit on the bike in your normal riding position. Twist the control housings and handlebar levers into the most comfortable position for you. Replace the two Phillips head screws on each plastic housing to secure them, then tighten the lever clamp bolts on each handlebar lever.

  • Double-check that every bolt is secured tightly, then take your Vulcan for a test ride to see if you like the feel of the lower handlebars and your new hand position.