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Step-by-step: How to swap the handlebarUpdated 5 days ago
Handlebar Swap (General Guide)
Swapping your handlebars is a straightforward process, but it requires care - especially when dealing with brake lines and internal wiring. Follow the steps below for a safe and clean handlebar replacement.
Step-by-Step Handlebar Removal
Disconnect the brake line.
Mechanical brakes:
Unscrew the small nut at the end of the brake cable housing (next to the throttle). This exposes the slit that allows the inner wire to slide out of the brake lever. Then simply take out the end portion through the second slit which is held by the start of the inner brake lever.Hydraulic brakes:
Disconnect the hydraulic hose at the brake lever using the retaining nut. This will expose the olive fitting.
Important: Keep the hose pointed straight upward to prevent fluid loss, tying both lines together can help keep it pointed upwards.
Remove the handlebar assembly.
Locate the bolts where the handlebar clamps to the stem. Loosen and remove these bolts to free the assembly.Expose and disconnect internal wiring.
Carefully slide the handlebar upward from the stem just enough to reveal the internal wires (COMM cable and LED wiring).
Disconnect all connectors so the handlebar assembly is fully detached from the scooter.
Reinstalling the Handlebars (Reverse Steps)
Reconnect internal wiring (COMM cable, LED cables, and any accessory wires).
Slide the handlebar assembly back onto the stem and align it properly while making sure no wires are crushed.
Reinstall and tighten the handlebar to stem bolts until the handlebars are secure.
Reconnect the brake system:
Mechanical: Slide the brake wire back into the lever slot and tighten the retaining nut.
Hydraulic: Reconnect the hose to the lever and ensure the fitting is secure with the retaining nut.
Test brake function before riding - some adjustment may be required.
Recommended Tools
Allen keys (various sizes)