I just bought some different bars for my 03 heritage and would like to hide the wiring inside. I have never done this. How big of a job is it on this bike?

 

Not hard at all... Just be sure to mark everything well, the only gotcha I had was the front brake light switch broke in the process. If you have a service manual, the process for protecting the switch is outlined there.

My Chubby have the stock wiring hidden inside without any extensions. The cables are all +4 so that will give you an idea of how much excess you have.

 

It's only 6 wires on each side.

Once you pull the connecter out from the under the tank do this:

Look at the back of the connector where the wires go through, and you'll see tiny numbers next to each pin. Note the number and the color of the wires.

The number layout should be similar to:

6 1
5 2
4 3

Pull off the small rubber gasket on the end of the connecter.

Use a small flat blade screw driver, and carefully pry out the orange tip from the end of the connector. Go slow, and it will come free.

Look inside the connector, and you'll see a tab for each pin. Gently pry those tabs, and the pins can be pulled out the back.

Assemble in the reverse order.

 

Does the tank have to be removed to get to the connectors?

 

Depends on how much dexterity you have in your fingers!

At a minimum, it needs to be slid back to access the connectors. Removal makes it really easy, but it's not required.

 

To slid the tank back do you need to disconnect anything or just unbolt it?

 

Front blot, rear bolt, and quick disconnect the gas.