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DRZ400 Aftermarket Handlebars
While most of the factory DRZ400 components are of a reasonably high standard, the factory DRZ400 handlebars are not that strong and can easily bend in a drop or crash. Replacing the factory DRZ400 handlebars with a strong aftermarket set is a great way to ensure you’re not left with bent bars mid-ride, plus of course improving the looks of your bike :)
There are a number of good bars on the market, I am quite fond of the Renthal 1 1/8 FatBar 603 bend in combination with BRP SUB mount triple clamps for adventure riding. Below is a set fitted to a DRZ400 build.
Renthal 603 bend mounted in BRP SUB mount triple clamps.
The controls on both the throttle and clutch side have a small locator pin that corresponds to the holes in the handlebars. One locator pin on each side, two locator pins in total. These locator pins lock the controls to the bars and stop them spinning. While there are many "how to" guides that say to grind these locator pins off when installing aftermarket bars, you'll be left with controls that spin on the bar when you go to indicate, switch to high/low beam, start the bike or use the horn. To do this job right, you'll need to replicate these locator holes in your new bars.
This is the factory DRZ400 handlebar with the hole drilled on the clutch side. The objective is to measure the distance from the end of the factory bar to the centre of the hole, then drill this hole in your new set of bars in the same location. IMPORTANT NOTE: the distance from the end of the bars to the centre of each locator hole is different on the throttle side and the clutch side of the DRZ400. You'll need to measure and drill both holes independently to get the correct hole placement.
Here you can see the 5mm locator hole drilled into the new bars ONLY to the depth required. On 1 1/8 bars the hole does not need to be drilled all the way through.
The clutch side control fitted to the bar with the locator pin locking it into position.