Replace handle bars
Mine had wiring inside the bars as well. Basically I removed the controls from the bars, and removed the 2 bolts holding the handle bars on. I removed the RIGHT side gas tank after draining it. I intended on cutting the wires to the connectors, pulling the wires out of the old handle bars, and pulling them back through the new bars. Note: Mark the black wires very carefully, since there were 5 black wires in the two connectors and they are all unique wires. The colored wires were easy, just match them back up. Several tricks I found on line. Use a string and a bolt to fish a pull line down through the new bars then pull the wire bundle through. This worked great on both left and right wire bundles. I then bolted the new handle bars in place and remounted the controls. I then replaced the shrink tubing up the bundles that hid the actual wires as they came out of the handle bars down to where I cut the connector wires, behind the right side tank. Next I stripped and tinned all the wires I cut (twist and get a little solder to stick on the wires) and stuck little pieces of shrink tubing up or down the wire so after I resoldered the wire I could shrink the insulation back over the splice. I picked up the shrink tubing and some extra wire a home depot. I had a soldering iron, and heat gun so away I went connecting the dots again. Litte tedious but hey. It saved me somewhere between $500 -$700 bucks which is what the harley shop quoted before I started. I tested each function, then reinstalled the gas tank and tightened up all the stuff. Below is the pin out in case you do loose a wire marker, like I did. Good Luck.
Nov 10, 2008 |
Harley Davidson FLTR Road Glide...