Back during the Bethel crit series, I was having some trouble with my shifting. While I eventually discovered the primary reason for this, SDC and I thought it might also have something to do with my Campy Veloce levers and cables. He suggested I try some Record levers he had lying around, and I had some brand-new Nokon cables I hadn't installed yet. Thus, a fun Saturday afternoon of wrenching was planned.
Working with an experienced helper (actually, I was more the helper), things went very quickly. The project was pretty straight-forward: Remove hoods, remove bartape and "under tape," remove cables & levers, reinstall all the new stuff. But once we got everything off, we made quite a discovery.
My handlebar was bent.
Certainly not bent enough to notice - otherwise, I would have noticed long before then. But apparently, my last couple of bad crashes - both on the drive side, unfortunately - must've banged that right side of the bar pretty good. I'd noticed after my crash last October that the tape and hood on the right side were pretty well banged up (though not enough to justify changing it), but I had no idea how hard it'd been hit.
The right drop was bent in about 1 centimeter.
Not having a spare bar lying around, and the hour beginning to get late, we decided not to bother installing the new silver bar tape and new red Hudz opting instead for keeping the scraped up Hudz for now (still red though!) and "temporarily" wrapping the bars with nondescript black Bontrager tape (which thankfully SDC just happened to have with him).
Fast forward a couple months. I've raced with that setup just fine. The Record levers are AMAZING (natch) and the Bonty tape is cushy. In the meantime, I got a new bar and just this past weekend got some time to install it.
Swapping out a handlebar should be easy - especially with the new stems that have the removable faceplate - and it is. But being my first time - and flying solo this time** - I took my time to make sure I did it right.
I took a LOT of time - 3 hours in fact(!). There is no way that it will take you as long. But I did take lots of pictures so you'll know exactly what to do if/when you ever need to change your handlebars. Follow along and I'll show you how, step by step. I (almost) guarantee it'll take you longer to read this post than it will to actually do this project.
(as always, you can click on the pic to make it larger for more detail)
I have a workstand, but mounting the bike in a trainer keeps it lower as well as secure. Just be sure to put a riser block under the front wheel to keep things level. I forgot. You'll discover why this is important.
Here's the "before" shot.
First remove hoods and tape. You'll see both sides started here. You start from the top of the bar.
Next, remove the "under tape" - the electrical tape securing the cables to the bar.
Before you remove the bar, make sure that the bike is level side to side . . .
. . . this way you can take a reading of how your current bar is set-up (tilted up, down, or level) using a simple bubble level. This makes your current set-up easier to replicate.
**NOTE: Remember either to make sure your bike is level fore & aft beforehand (e.g. by raising the front wheel if the bike's mounted in a trainer), or make sure you don't change anything between reading your current setup and installing the new bar. These readings must be done so that the only variable is the bar itself.
"Under-tape" removed, cables free.

I almost forgot: label the cables so you can put them back in the same order/location (a tip from SDC).
There's a fixing bolt in the lever that tightens a bracket around the handlebar. You'll of course need to at least loosen this bolt in order to get the levers off. I thought loosening would be sufficient - thinking I could just slide the levers off. But due to the bend in the bars, I had to undo the bracket entirely. But it's easy enough to put back together. I shouldn't have been intimidated by that - you shouldn't be either.
Levers off and dangling (gently), stem faceplate removed, bars removed. Bike looks weird.
I emphasize gently since you want to be sure not to mess up any tension/setting of the cables. I don't know if this is something you really have to worry about, but I did. I figure better safe than sorry.
New bar installed & dangling, faceplate loosely attached.
Yes, I know it's a Bontrager bar on a Cannondale bike. But Bontrager makes a good bar and they're a sponsor, so that's what I use.
Before tightening the stem faceplate, be sure your bars are set where your old ones were (assuming you don't want to change the position of course). This is where I discovered that "level" according to the, uh, level, wasn't "level" in relation to the bike. Because I'd forgotten to make sure the bike itself was level - and it wasn't since the rear wheel was raised in the trainer and the front wheel was on the floor without a riser.
No matter though. Keeping the bike the same ("controlling" for that variable), I was still able to replicate my orginal bar position.
Ok, in case it hasn't already been made painfully obvious by this post so far, this pic reveals the extent of my OCD tendencies.
I just want to be ABSOLUTELY CERTAIN the handlebar is PERFECTLY CENTERED. You - and probably everyone else - will probably just eyeball it.
I'm using this tool to make sure the distance from the stem to the outer part of the drop is equal on both sides. In case that wasn't obvious.

After dialing 911 in the form of a panicky email and a quick search of the internet for "Cannondale Stem Torque Setting" I discovered that - DUH - the proper setting is printed right there on the stem, right where you need it.
Using "good mechanical practice," I snugged down the four faceplate bolts in "X" fashion (like you would automobile wheel mounting bolts) to insure that the faceplate seated evenly and the bar wouldn't move from where I set it. Then I used my new torque wrench (a present from Santa) to tighten the bolts to the proper, um, tightness.
Bar secured, put the levers back on, paying attention to the proper placement of the cables (guided by your little labels).
The Bonty bars have nice increments marked on each drop to help you position the levers at the same level relative to each other. Interestingly, even though there are like 10 different increments, I used the top mark. I wouldn't call my levers "jacked" but they're at least as high as Bontrager seems to think they should go.
And they're level with the top of the drop. That's the important thing.
Cables secured at many points by electrical tape (the "under tape"). Your bar is now ready for taping.
NOTE: If you either a) aren't sure whether you replicated your position perfectly (or at least adequately), or b) want to change your position, road test your setup before you tape your bars. You'll want to be sure everything is exactly how you want it before you tape the bars and fix everything in this position.
Living dangerously (despite my OCD) - or maybe it was just laziness - I decided I'd put everything back perfectly and was confident everything would feel exactly the same as it did before. But I at least got on the bike and rested my hands on the hoods and pedaled a bit. I also checked my shifting while I was at it.
Yup - everything felt fine. I was ready to tackle Bar Taping.
If you've never taped your bars before, do yourself a favor and do what I did. Check out this great, step-by-step How-To article.
Go ahead. I'll wait.
Now that your back, if you followed the advice in that article, your bars will look (something) like this:
All done. Nice new Fizik silver bar tape (to match the silver in the saddle), and nice red Hudz hoods to match the frame, and tires (this shot makes everything look orange, but they're red. Deep red). And not-so-nice basement wall that had to be cut recently due to flooding.
The last step is the most important: Road test everything if you didn't already (see above). You'll want to be sure that everything feels right and that your shifting is still good. I'd planned on road testing, but Sunday and Monday slipped by without my even turning a pedal.
I'll get to test it after work tonight though - at the first Tuesday Night Crit at the Rent'. Nothing like a little racing to really test a setup(!).
So there you have it. Next time you change your bars out, let me know how long it takes you. I'd be willing to bet you'll beat my time. Let's just say I won't be applying for any bike shop mechanic jobs anytime soon. Yeah, everything will be PERFECT when it's done, but I'd only be able to work on about one bike per week. In other words, I (or my shop) would lose my shirt. Best to concentrate on the one bike I have.
**Oh - when I said before that I was flying solo? I lied. I actually DID have a helper . . .
