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Heated grip install help on KST mini’s

Old Jun 20, 2023 | 02:17 PM
  #11  
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Originally Posted by TnFatboy
chopper_man-
I think I misunderstood. Are you saying that the TGS harness already contains the heated grip harness in it ? I got my bars off, and thats what it looks like (see pics below). If that’s the case then I only have to redo the left side.

All 4 harnesses go to right side, it looks like the plug on the far left is the heated grip connector
Correct, TBW grips utilize the wires already there. At the outside end of of the TBW unit is a small cap that needs to be removed and you will see the 2 pins the throttle grip plugs in to. Black and white wire connector is where the left side grip wires jump to.
 

Last edited by chopper_man; Jun 20, 2023 at 02:18 PM.
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Old Jun 20, 2023 | 02:52 PM
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I will add that since you removed your bars completely - there is a decent chance that you can fish the heated grip wires in the left bar through to the center opening “without” un-doing any of the existing wiring pulled through - this is a good video showing everything and this guy did, and he did “not” remove the bars completely

 
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Old Jun 20, 2023 | 04:56 PM
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Originally Posted by TnFatboy
What bars did you install? With the 12 inch KST’s, the controls needed extensions. The clutch and brake cables were long enough but had to be rerouted somewhat
I bought the Khrome Werks 2+2 bars. They are taller and come further back than stock. The clutch cable barely made it after some rerouting. My hand controls may have needed extending if I had found a way to run them internally. I bought extensions for the heated grips and the hand controls, but only ended up using the heated grip extensions.
 
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Old Jun 20, 2023 | 05:19 PM
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Thanks everyone for the tips. I watched that video too earlier…I already pulled the left clear, those pointed bars are a bitch to get anything through, there’s no way I would’ve gotten a pull line through with the other wires in. I tried weed trimmer string with the left side empty and couldn’t even get it through with compressed air, everything ***** up when it hits that corner point at the peak of the bars. I ended up getting some rope through (I kept the rope that I used two years ago) with the air compressor, and started de-pinning the grip plug and had to stop for dinner company and getting up at 1:30 am for work. Will try to finish tomorrow. Much appreciation to everyone
 
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Old Jun 24, 2023 | 07:58 AM
  #15  
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I finally got a chance to get back to my grip install yesterday. Man, what a major bitch…I really wish I’d have added the heated grip extensions when I changed my bars. The problem wasn’t that the wiring wasn’t long enough, it was just very difficult to get everything in the left side due to the bulk of having three different harnesses going through. That, and HD’s instructions are just horrible, I have a hard time following them, maybe that is a “me” problem! Anyway, I ended up ruining the heated grip plug when I tried to de-pin it, and spent the morning running to my local dealer and a few other places looking for the pins…dealer had the plastic housing part of the plug, which I bought, and thought I found the pins at a small indie shop, but when I got them home they were just a hair to small. I didn’t want to wait a week to get them ordered, or drive two hours to the next closest dealership (which is what I should’ve done) so I just spliced the end of the control to the longer extension that was included in the Harley kit, added some heat shrink and taped the hell out of it. The instructions, as I said, are confusing in that they give you no clue as to where to find the on-vehicle connections for the heated grips, and my service manual was actually no help either…but thanks to the video someone included in one of the replies to this thread, I was able to find my left hand connection, which was tucked way up inside the fairing, with a cap on it. I never would’ve found it without that video. I never did find the right side connection, and again, the instructions get confusing…in one of their diagrams it shows a “heated grip interconnect” that is zip-tied with other wiring along the neck, in front of the riser, and impossible to get to with the fairing on, even tilted all the way forward. I never did find this interconnect, and started wondering if the instructions meant for me to use one of the included jumpers to create this interconnect to jump the power to the right hand side, from the remaining left hand connector. Duh…it’s obvious now that’s what it meant after spending an hour looking for it and going back through the replies in this thread, but again, the instructions are very unclear. Anyway, I laid the bars out and ran some temporary jumpers to test the heat on the grips before I even mounted the bars, and they were working just fine, so I got them mounted, everything plugged back in, hand controls mounted and plugged in, tested everything again and it’s all working like it’s supposed to. All I have left to do is reinstall the perches, clutch and brake controls, check for rub and pinch points with my wiring, install outer fairing and that’s it…sorry for the long winded post-I hope my mistakes and questions, and the replies you guys posted can help somebody that’s trying to do this job-as alway, thanks for the tips and help to everyone! I’ll throw some pics up when I get back out there in a few.
 
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Old Jun 25, 2023 | 11:56 PM
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LOL yeah, doing the total in-bar wiring is a major PITA! Even with just 10 inchers, I had to get the KST extensions for mine after running them inside the bars with the switch pack wiring.

They sure do work great! I got into some chilly weather in Idaho last week (26 degrees and snowing) and had them on just the #2 setting, and they were toasty!
 
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Old Jun 26, 2023 | 11:38 AM
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Yeah I got it completely finished yesterday and buttoned up, they work really well. I’m glad I made the switch, my grips (especially the left) were worn out so I upgraded.
 
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