Introduction: Straighten Bent Handlebar on Motorcycle

I managed to fall with my motorcycle so that the handlebar ended up being quite much out of align with the front wheel. First step (if the location of the damage is not obvious) is to release and examine fork tubes. For that see for example http://faq.ninja250.org/wiki/I_need_to_realign_my_forks_and_front_wheel#Front_end_alignment_v2 . If there is lot of damage, get a professional to help or buy new fork tubes and other suspicious parts, your life depends on that. I also started the repair releasing the fork tubes from triple clamp and aligned things just eyeballing the centre part of the fork and wheel. And then it was obvious that the main problem is handlebar itself. Here's how I got things into bearable alignment again. This is no precision work, I can excuse myself with the fact that the handlebar was out of alignment already when I bought the thing, my fall just made it worse.

Things needed:
  • sturdy tree or lamp-post or something like that
  • strong beam that fits between fork tubes and gives leverage to keep fork from turning
  • cargo lashing belt
See images for usage. The point is to pull the bent end of handlebar towards the post with the strength a cargo lashing belts lever gives and at the same time use the post and beam to prevent fork from turning along with the pulling force.

Keep bystanders on safe distance and consider wearing protective gear in case the beam breaks or something else goes flying under the tension.

Comments

author
crazypj (author)2014-05-08

Doing the right side like that could damage the throttle tube.

It's also a false economy, the steel bar will not be as strong as it was before the bend and will bend even easier next time possibly causing far more damage.

I think the ZX7 has aluminum bars, they will probably snap if you try and straighten them?

author
sfraneta1 (author)2014-02-11

Awesome thanks...have the same problem. I bought my zx7r with the handle bar bent and definitely looks like it will do yhe trick.

About This Instructable

16,825views

4favorites

License:

Bio: Maker of all trades ... or at least many :) Interested in electronics including programming, woodworking, how to grow edible plants in cold climate of my homeland ... More »
More by Libahunt:Lighting Under DeskLittle trick for desoldering through hole componentsPlywood mailboxes for apartment building
Add instructable to: