HOW TO: Install Z Bars on Harley-Davidson Sportster

How to install Z Bars, grips, and new brake line on the Harley Sportster!
Ms. Blockhead didn't like the stock bars on the Harley 48, and loved the look and feel of Z Bars. So she decided on a height, I ordered everything we needed and surprised her with parts for Christmas! We installed the Z Bars soon after!
► PARTS USED:
- Z Bars 8”: amzn.to/2CIvjYf
- Arlen Ness Grips: amzn.to/2DdYOSY
- Burly Cable Kit: amzn.to/2mdg6aw
- Brake line only: amzn.to/2CMUj0N
- Brake Bleeder Pump (Stockton): amzn.to/2CKdNmE
- Brake Bleeder Pump (cheaper): amzn.to/2mcWAuV
- DOT 4 Brake Fluid (Motul): amzn.to/2FjYNxp
- WD-40: amzn.to/2CMUfhg
- Blue Thread locker: amzn.to/2CLMAjo
- Magnetic Bowl: amzn.to/2CJJY5r
- Torx Bits: amzn.to/2mdgQMQ
- Hex Bit Sockets (SAE): amzn.to/2FjYZN9
- Shop Towels: amzn.to/2EspcIj
The process should be nearly identical for most Sportsters. I know my 2013 Iron 883 was the exact same (except I installed drag bars so I didn't have to change the brake line.) The bike worked on in the video is a 2010 Harley-Davidson Sportster 48. Based on your make and model year, your experience may vary. Please note the disclaimer below*
As always, thanks for tuning in! Be sure to Like / Comment / Subscribe!
Till next time, ride safe out there, & stay vigilant!
Deuces!
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► BIKES:
2017 Harley Low Rider S (FXDLS)
2015 Honda CBR1000RR
2010 Harley 48 Sportster
1987 Honda Rebel 250
▬
► LINKS:
Behind the Scenes!
• / blockheadmoto
My Gear @ Amazon:
• www.Amazon.com/Shop/Blockhead
Blockhead Merch:
• bit.ly/Shophead
Social Medias:
• Instagram - bit.ly/BlokHdInstagram
• Facebook - bit.ly/BlokHdFacebook
• Twitter - bit.ly/BlokHdTwitter
▬
► MAIL:
Blockhead Moto
PO Box 18
Windermere, FL 34786
▬
Music:
Tonez & Re-C - Kyoto: bit.ly/2o95eOL
Creative Commons - Attribution 3.0 Unported - CC BY 3.0: bit.ly/2o941XS
Music provided by AL: bit.ly/2o9aKkH
________
*DISCLAIMER:
This is only a guide, and not meant to be taken as the only means of completing this job. I assume no responsibility and am not responsible or liable, directly nor indirectly, for any damage or loss caused or alleged to be caused by or in connection with use of or reliance on any such Content, site or resource.

[@TheHarleyTech]

Solid work for a “not licensed tech.” Keep up the good work on the videos. I enjoy the hell out of them!

[@MeestahChuklesOne4]

Threw a set of Biltwell Keystone Z bars on my 883 as well as my own exhaust and intake install. Still tuned in cause I'm seriously diggin y'all's videos together. Working on your own bike is soooooo much more satisfying than taking it in. All the leftover scratches and whatnot from my mistakes are just added character. Keep up the good work brother!

[@Grimgeist]

Can't wait for a dual vlog on both HD's. Both bikes are awesome and they deserve a video! I had a Sportster Nightster 2010 and I traded up to a 103 Softail Slim 2015 last year. I miss my sporty but couldn't be happier about my Slim. Love the vids so keep em coming!

[@mattvanshufflin9986]

Awesome install videos man. I’ve been loving learning how to play around with my first bike (an 883) and have used many of your install videos. Dope content!

[@ronaldanderson3816]

My wife and I were able to find the brake line we needed and install it thanks to this video. Thanks for saving us some money.

[@trigas55]

Thank you Ms Blockhead and assistant. With your excellent tutelage I am happy to report a complete success.

[@oscarmadera2669]

Hell yeah great vid!! I was just looking to replace my bars and was worried about the cables but this video just cleared it all up!! Great work!!!

[@williamgarcia102]

I love this video just for the fact that your girl supports your hobby. My gf asked me to come visit her yesterday and she specifically asked me if I could bring my Harley instead of my car. I gave her extra loving for that.. good job and nice video.

[@CactusJack252]

William Garcia I hope you rode her better then the bike!

[@joetroutt7425]

You rode over there and she rode you back.

[@andysomerville8761]

hey guys thanks for the video , started watching your channel about a year ago and yesterday bought my very own nightster 1200 my first Harley you guys had a hand in that, love the channel

[@HeyCoolStoryBabe]

I love how he referenced Revzilla’s beard scale of difficulty with a 1 bearder being easy to a 3 being hardest on the BSD. Lol 😂😂

[@adamstainer9577]

Love how involved Miss Blockhead is, after my wedding and honeymoon March/April 2018 (in Davenport FL!) I’m hoping to get a 48 and an 883 for the Mrs and I. Not so easy finding an abundance of Harley’s over here in England without blowing huge bucks. We’re 26 and 23, I’ve only ever owned an R6 and the fiancé isn’t so keen on riding....Keep up the good work you two, every video of the two of you is ammunition for me to use on her:)

[@tccoup355]

Wow what a huge difference those made, for the better of course. Awesome!

[@dustinhxc]

This is awesome, thank you! Definitely switching to these bars when I get a 48.

[@Cyril_Harperink_87]

Definitly looks better than drag bar. You did a good job. And thanks for advices.

[@blazekeith2648]

You guys do a great job going into detail! Love the wat it looks now im gonna put those on mine now thanks for the video!

[@FocusReflect]

Nice man! REally like these duo vlog build series :) Can't wait to see more!

[@Boobtube.]

great job. I liked the paper shop towel with hole in middle to fit around the brake reservoir when filling it with brake fluid.

[@XceedDriver]

Thank you for this video! I am actually looking to add some Z Bars to my 2015 Iron 883 and have been wondering what extensions I need to do. Much appreciated!

[@MrAndrew1953]

Very good step by step guide - like the Zbars - look much sharper than the standard curved bars.

[@richarddelotta2586]

I used this vid to help do the bars on my bike. Thanks for what you do

[@grandpamcnuggets]

Wish I found a video to help me replace my bars instead I was an idiot and took it to the dealer because I wasn’t confident! FML! But I’m glad you put one out! When I get another Harley I’ll reference to your video!!

[@Taino871]

Cool Mrs Block is left handed like my Queen is. We also work very well together. It is refreshing to see couples do projects together. Awesome stuff, Awesome video. Thank you

[@shaunmarie]

definitely wanting this for my 883 iron. they look so good!!

[@THEBIGCHULETA]

Wish I could have seen this when I did my 48! Great bike.

[@rayroman4111]

I wish i'd have a wifey that liked to work on bikes with me like you do, bro. You're both lucky. I really like the two of you doing this together. Big up! :)

[@pim1234]

Isn't it his daughter ?

[@moonshineman33]

@@pim1234 no it's his girlfriend or fianceé or his wife. Not sure which one.

[@AlexD02]

I agree. My girlfriend doesn’t like that I have a motorcycle at all. Hopefully she opens up to it goes on a ride with me soon. I even have a backrest for her lol.

[@badboybootz8]

Why do y'all want girls that act like men thats so weird to me

[@zachbenson1780]

@@badboybootz8 Why are you sexist?

[@luisbiascochea2829]

Hey, happy New Year to you Year to you and ms/Mrs blockhead just got home from work watched the video as always very informative and to the point....😎😎😎

[@patmanwainwright3423]

Looks good Z bars suit Sportster bike is coming along nicely good work mr & mrs Blockhead

[@chriserrazuriz6666]

Good video! Z bars look great!!! I'm getting some for my Yamaha bolt.

[@PaulG.333]

Must watch, very informative, thanks for sharing.

[@uscg1381]

Beautiful! Getting them for my bike!

[@larryavilez8060]

Man thank you for this video I'm currently about to put 14inch apes on my sporster 72 I'm surprised you didn't take off the tank every video I've seen they take off the tank now I know it really not necessary

[@planefloat]

Hi, a very detailed installation procedure! Have you had a chance to try it out on the highway? Is the more upright sitting position more or less comfortable at 60-70 mph? I have ordered 12" Z-bars for my '06 Sportster, the 8" or 10" may be a better choice. Did handlebar vibration change?

[@DuKeEst]

Sweet dude.. i will be going to do that job . In few months.. soo i appreciate the video. Good to see what i have to go throw !

[@BRUISER1]

Great video. Very thorough 🤙

[@andyraider5952]

Man I wish I had friends like u guys I was a victim of a hit and run 😭 and now I gotta replace some parts on my 883 iron and thats why I'm here

[@motorcyclemichael2938]

Im glad you went with the z bars and not the drag bars! Looks great

[@robertjohnston25]

Shoulda went with the shorter ones

[@joetroutt7425]

@@robertjohnston25 yeah like his stock ones.

[@HarleyFirestorm]

The Z bars with pull back are great, I have straight Z bars, look good but are not the most comfortable.

[@SevenDragonBall]

I follow your steps and I success install it ,Thank you and your assistant!

[@Tarrnation]

Nice Bars ! Awesome job well done.

[@jakedunston5222]

For not being a mechanic, I was really impressed with your professionalism. Some more lighting would have helped. Great job!

[@angiebobangin]

Such a helpful video! Thank you! Also I have a question for Mrs. Blockhead. I’m not sure how tall you are but I’m 5’5” and I just bought a Forty Eight I’m looking for handle bars that will help me sit more upright without locking my arms out. I’m wondering if these Z bars helped with that for you? I’d really appreciate any input before I spend money on new bars 🙏🏼

[@samrodriguez9864]

Nice work . I think I’ll save this video so when I get my z Bars I can use it as a reference.

[@donaldwest9373]

Crazy how changing the handlebars gives the bike an entire new look

[@jtodd0221]

I just got an 883 and this is probably going to be the first thing I really change.

[@coreyreeb]

Hey man, any info on your front headlight setup without using the classic sportster visor? Looks great, thanks!

[@LastChanceFossil]

What a wife and husband duo! love it

[@trevslife1119]

For a 2019 Harley iron 883 xl883n what brake line should I buy and it has abs do I do anything with that? I’m having trouble finding a good brake line that matches my model number

[@Asxzasf]

Thanks! Loved the tutorial, great job. I thought you had merchandise for sale from blockhead...

[@69FOSTER]

How do the Z bars affect the riding position vs. the stock bars? I have a 2018 Sportster 48 with stock handlebars and at 5'9'', I'm leaning forward more than I'd like and would prefer to lean back a little more and be more upright.

[@AK4TF]

The cable you linked for just a brake line, will it work on a 2017 883 iron? Listing says no but how different could it be? Can't find an individual longer cable without going to a HD dealer.

[@labratmanny1251]

Thanks, I needed that information awesome

[@JIMBOBALOU]

To properly adjust the throttle cables you need to pull the air filter to see the butterfly valve in the carb or throttle body btw. There's probably videos on KZbin to show you how.

[@jontest5718]

I just ordered some 8" bars not two days ago. The gentleman claimed the bars should be good with stock cables, we shall see. Enjoyed watching this and getting to see the finished project

[@joshouten377]

Jon Test how did it go? I’m in the same boat, just ordered some 8” apes and would like to know if I have to get cables before hand

[@nasomaz]

I'm in the same boat; I ordered some keystone xl bar (8.5 rise). All the reviews say that only the break line is short but you can unmount it from the bracket and bend the metal part to make it straight and it will have room to fit so problem. Did yout install go well ?

[@jontest5718]

It went fine, the stock bars on my bike were a bit larger so the stock brake line ended up being ok. Unfortunately I have not had a chance to ride the thing because it came out of storage and is only firing on one cylinder. Ongoing cluster fk trying to resolve it.

[@nasomaz]

Glad to hear bars were fine. I hope you will resolve the mechanical issue with your cylinder !! Evos are bullet proof I am sure you will figure it out.

[@BloodNuke67]

Okay so i just bought my new 883 in new Smyrna and confused about the bars, it has 2 inch risers with drag bars, what do i need to buy to replace the risers and put the z bars on?

[@chriscichy1845]

Hey man got a question from ya or anyone with more knowledge then me lol. Currently have 16” bars wanting to switch to 12” guessing I would have to get new clutch and brake cables or could I use the same ones ?

[@Paynita]

Does the handle bar need to be dimpled or not? I am upgrading my 2015 48 Sporster and shopping around bars. Thank you!

[@younonguyen5183]

Blockhead, I’m needing an advice on installation of drag bars on sportster 48. Do I need to buy risers for it to clear the upper fork nuts? And do I need to relocate the front turn indicators? I remember you had a 48 so I figure you be the best person to ask. I can’t find concrete info. Thanks again

[@rebel_ltz]

Man, I just replaced my handlebars on the Iron and because I didn't like the new ones I had to replace them again to the stock ones. (And I will have to do it again when the new-new ones arrive.) The whole process was 2x2 hours in the cold winter wind... This video gave me serious PTSD. Also for the other guys out there planning to change to taller bars: If your bike has ABS, your front brake line will be much more complicated than shown in the video. In this case be prepared that you will have to visit a brake specialist service since the stock ABS brake lines are pressure fit to the lower triple tree ABS unit and you won't be able to change to longer ones yourself (without fancy tools).

[@djohnson3678]

ouch! good ... looking out for us man.... high 5 !

[@zacshares3837]

hey blockhead, how was the quality of these bars? i was gonna order some for my 48 at 12'' and wasn't sure if i should save a lil and get these or drop more and get licks or other known brands. thanks

[@jonbonjovi6912]

So the little brass piece. Does the solid part face towards you or away from you when you put everything back on?

[@XionZ99]

I have ABS on my Iron 883, I plan to put 8 inch bars on. Where can I buy a brake line for ABS equipt model? Haven't really looked for one, just need some recommendations.

[@jwill1782]

What’s up Blockhead question I have 14 iron I want to instal 10” mini apes on it. What cables do I need?

[@obijuankenodi]

Hello!! I have a question. Did you change the electronics cable? I mean, I'm installing 14'' Zbars, but I don't know why I think the electronics is not going to be enough. Also, you only change the brake line? Do you recommend buying only the brake line?

[@michaeltayer6857]

im planning to change my handle bar to 10" Ape Monkey Hangers Handlebar. May i know if i need to change the complete cables or the brake front cable only ? kindly advise

[@jasonsanderson9385]

Great Video!! Next thing is to switch out my Drag bars to Zbars

[@coyrodgers]

Would you have to change any fluids or lubricants if changing clutch cable??

[@jpl8085]

Looking to put bars on my 48 cause i don’t like the stock bars. If i got 10” bars do you think i would have to do more then just the brake line? If so i might just get 8” too. I am 5’ 8.5” so i want something that i can be more upright on the bike instead of leaning so forward.

[@hogginwithpa5603]

Long time watcher ! So about those little brass by throttle / clutch cables , say you did lose them, any idea where I could locate new ones ????

[@chriscichy1845]

Got a question for ya boss not the best or most knowledgeable guy with motorcycles as I am new to them. For the new break lines and such what would you prefer is a good time to get new ones ?

[@justinvenia8497]

If I want to put the harley tallboy handlebars do you know if i need to replace any of the cables and wiring?

[@TheVikingBiker]

Looks great! how did you set the angle of the bars? was it just personal preference or did you try them out?

[@yudhistirabaso6221]

Can you make instruction video for z dragbars wiring installation.. i will very appreciate it..

[@jasedavids]

Did you not have to extend the wires to the controls i have a 2004 and the wires seem tight is there extra length somewhere you can find? I have the favrory 6 inch riser

[@Scooter3194]

My stock brake cable is 39 1/2” long I want 8” z bars what size brake cable do I need 42” or 44”

[@americanhooligans]

Will 4 inch z bars work with the stock brake line you think? I have a 2016 48

[@resone3645]

With the Zbars, did you have to do anything extra to flip your mirrors? I tried flipping my mirrors on my nightster with Zbars and it works but I can’t see shit...so do I need to get extenders for flipped mirrors to work on the Zs?

[@neezaralinaveed3566]

it looks amaaaaaaazing 💯

[@braydentaylor880]

Hey man, I got a 2016 XL883N wandering if I bought these same bars do you think I could still use the stock cables?

[@hendy1388]

Very helpful!!!good job..

[@MrRollie51]

I like the Z bars much better than the Drag bars Hey great video!

[@thechappells2599]

Hey blockhead I was wondering how much taller than stock the 8 inch bars are ?

[@pappabearj5683]

Blockhead I got my wife her iron 883 and she wants to replace the bars. What brand would you recommend.

[@BlueRogueDragon18]

How does she like riding with this z-bars and could I fit a front cal light cover? With those on? Cuz I have the slats light cover and want to put a cal on top of that.

[@cristianvigueras2757]

Do you only have to bleed the lines if you’re changing for the extended brake lines? For example if I change my bars to the stock ones I don’t need to do this step?

[@sallyannealvarez13]

great can you do my sportster? lol i have a superlow and want that exACT SIZE LOOKS CLEAN

[@krseper]

What size are the bolts bits on the top clamp/triple triple tree where the bars are attached too?

[@thechappells2599]

Do you know what size the stock bars are ? I’m trying to figure out the height difference

[@cnikola227]

Do the riser bushings have to be replaced when replacing bars?

[@joseesparza9119]

Hey man do you think this will fit on a 2020 sportster with mini apes

[@orangindonesiatinggaldiame6420]

hi I just bought 2021 sportster 48. why does it idle so high. any tips? thanks in advance

[@montechristo0214]

Hey,you know what is the highest rise i can use without change any cables?iron xl883n abs 2017?thanks. Nice vid.

[@PkwyDrive13]

Some people have gotten away with 8in bars without changing anything, but I'd say 6in for sure.

[@CactusJack252]

Great work. Up next should be an exhaust system or a set of slip on mufflers.

[@Svtdude302]

Great video! Looks like you used the “10 inch cable kit. I can’t seem to find the “10 inch cables for Sportster 48.... the sites seem to all say they won’t fit. Which one did you order. Thanks

[@ikarichevystar]

Macdude Rider i have the same question? I want to put this zbar, but i dont fine de line

[@beaner_5475]

Do I have to change the break line if I put 5 inch bars ?

[@TonyMyersxx]

Can you provide a new link to bars. iv looked on amazon and i cant find the style you have. they have multiple "z bars 8 inch" but without the dimple and nerald middle.

[@flytheedge]

Hey, Blockhead. How do you like those Ryco Handlebars? Are they manufactured in the U.S.? Any warranty?

[@thechappells2599]

Do you think the stock clutch line will fit 10 inch bars

[@daemonmanson99]

Would I need a brake line if I went with the 4inch z bars

[@jeremychildress8701]

Hey Block What is the pull back on the new bars?

[@randellalexander7870]

Nice vid bro where did you get that bobber seat?