Anyone change out their Handlebars ?
I didn't try to solve the problem in the abstract (figuring out cable lengths), and went ahead and did the install and then went to the dealership to source the longer brake line and turn signal wires. Luckily they had some in stock (they were all 2-3" longer than I needed, but that's what they had). Inventory is low and many of those items on back order - that'd be the biggest variable.
See posts #2687 and 2693+ of "what did you do...2018+ Softail" thread (last couple of pages). I'm glad I did mine myself, it wasn't that difficult.
no process for the throttle - pulled it out and it only goes back in one way.
I just bought cable extensions for the turn signals and a new longer upper brake line.
The thing is, there's more wiring length than you might realize, and some rerouting of the clutch and brake line can be done without needing to even detach them from their components, you can just move the cables/lines around some. So, if HD is quoting you $900+ dollars (
I've done 4 sets of bar changeouts and only had the clutch cable done because it was in for 10k mile service anyways, I was going from Reach to 12" apes, and looking back I didn't even need to do it, it's too long now.
As far as doing the throttle by wire, I was worried, but it's actually pretty easy. It has a geared throttle sleeve under the grip, so once you loosen the signal cluster, the grip will just come off. Then you unplug the TBW plug and gently pull the TBW piece, along with the signal wiring, out through the bars. So you're pulling on the TBW at the grip end, pulling the wiring out. When pushing it back in with the new bars, I lube them up with soap to make it easy, then just kinda work them back and forth until they make it through. A small set of needle nose, or a small screwdriver, helps with fishing the plug out of the handlebar hole.
Basically, handlebar changeouts are really easy unless you have to change the brake line, then it gets harder. Even if you have to do the clutch, just buy the longer upper, the new plastic Harley clutch cables separate in two so you can change the upper without having to mess with fluids or anything. Basically that $900 quote will only cost you the price of the handlebars and maybe the clutch upper cable if needed, as long as you can stomach messing with the controls and wiring, which isn't bad once you see how it works.
(oh yeah, even if you do need longer wires, it'd just be a matter of buying the extension kit, plugging it in, to make that wiring run longer, but same routing process. The main hangup is if the brake line will reach. Harley will say it won't, but it might. My stock brake line for the mini apes reaches with the 12" bars rolled back.)
Last edited by goodguybiker; May 8, 2021 at 10:19 AM.
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As far as the brake caliper stuff goes, I didn't have to mess with any of that so I'm of no help there, lol. Couple words of advice going in though, especially since you're just tinkering to see if it'll work without needing HD to do it all: The clutch is weird taking it apart, if you have to take the upper section off. Watch a youtube video on it and it'll make sense. It's also kinda weird detaching it from the hand controls (if you even need to go that far with it). On the hand controls, they're actually fairly easy to disassemble to get to the wiring when you fish it out, just make sure you don't pinch any wiring when you clamp them back together. They have little grooves and channels they sit in so everything sits right. If it seems like you're forcing something, you probably are, so just fish it around until it fits into its home. And finally, for the front brake line, I did have to unscrew the clamp that holds it under the fork tree for mine to be loose enough. It's not "right", but it's also not snagging / getting pinched or anything like that when my forks decompress and such. So if your front brake line is too tight, try unscrewing it from the fork tree clamp and letting it hang loose, that may give you the extra length you need. Just test it by pulling up hard on the forks to make sure it doesn't go too tight on you.
Let me know how it goes, I'm curious to know how much play the Slims have, or does ANY bar changeout force complete new wiring/clutch/brake lines.
The Best of Harley-Davidson for Lifelong Riders
REACH BARS:
Base Width: 8.25
Base Width UOM: Inches
Knurl Center-to-Center: 3.25
Knurl Center-to-Center UOM: Inches
Sold Seperately: Additional installation components
Sold In Units: Each
Material Content: Steel
In the Box: Handlebar only
Pullback: 2.0
Pullback UOM: Inches
Rise: 8.25
Rise UOM: Inches
Tip-to-Tip: 30.0
Tip-to-Tip UOM: Inches
HOLLYWOOD BARS:
Base Width: 9.0
Base Width UOM: Inches
Knurl Center-to-Center: 3.5
Knurl Center-to-Center UOM: Inches
Material Diameter: 1.0
Material Diameter UOM: Inches
Sold In Units: Each
Material Content: Steel
In the Box: Handlebar only
Pullback: 6.25
Pullback UOM: Inches
Rise: 7.0
Rise UOM: Inches
Tip-to-Tip: 31.75
Tip-to-Tip UOM: Inches
So you can see, even though the Reach bars have more pullback, its dimensions are actually kinda close to the Hollywood bars. It surprised me when i saw it because the Hollywood bars look and feel more flat and wide than they really are. So the difference may not be much from what you already have. I know when I pulled my wiring out for the original bars, there was quite a bit bunched up, I was like "wtf I've got plenty here" lol






