2005 Cycleworks scooter. I am trying to replace the switch housings. I am now on my second set. The bike has cable throttle control with switch openings that are very rounded versus square. The first set I purchased was part number 3800447 which is for a pre 96 model bike. The openings in the housings for the switches were very square and the right lower did not have holes for the throttle cables. The second set I purchased was part number 5000260 which is for a 2005 lowrider. Fit the bike well, the switch openings are more rounded which is what was on the bike however the openings for the throttle cables are not threaded. Just did the live chat thing with JP and they are now recommending 5000242 right lower housing however by the picture it is back to the square opening. This is also for a pre96 model which I don't believe is correct as the bike was built-in 2004-2005 timeframe unless they were using 9 year old parts which is possible. Does anyone know if any harleys around 2005 had lower switch housing threaded for throttle cables? I guess the other options I have is to either thread the housing I currently have (2nd set, 5000260) or change out the throttle cables. Can't wait to get this bike running and out of my garage.
scott

 

The `95 and earlier housings (OEM) will be more squared shape, and the throttle cable openings are threaded.

The `96 and later housings (OEM) will be more rounded shape, and the throttle cable openings are not threaded.

 

Thanks. So dumb question. Is there another motorcycle manufacturer that has similar switch housings? The bike has rounded shape openings and threaded cable openings.

 

Pre `96 have threaded holes for throttle cable, somewhat square shape.

`96 to around `06 have unthreaded holes for throttle cable, and are more round in shape.

Get the ones you want, and get the cables that fit.

The switches themselves are also not the same, if you use pre `96 housings, you will need pre `96 switches etc.

Also the clutch lever mount and master cylinder are specific to these years also.

They all must be from the same era.

 

Thanks. What I can't figure out is the switch housings that came with the bike have rounded switch openings and threaded throttle cable openings. I am definitely missing something just can't figure out what it is.

 

Post a pic, maybe someone will recognize them.

 

I just ordered pre-96 housings and switches hopefully the levers will fit. The next problem is the leads are not long enough to get to the brain so will need to be extended That is not difficult the problem is the splices will end up in the frame tube which I do not believe there is sufficient room to make. I will have to stagger all of them to get as much room as possible.

 

Why must the splices be in the frame tube?

You don`t have to leave the wires on the switches full length, cut them shorter if it will move the splice area to a more desirable position.

If you went with `96 and later switches you could have got them from Harley Davidson, and the wires are super long.

 

thanks Dan, wished I knew about the Harley wires before I ordered. Obviously the cables route through the frame, then through the center of triple tree and then into the handlebars and come out under the lever clamps. Not sure where else to put the splices? The cables are about 4" short of getting to under the seat and in the open for splicing. I am up for any suggestions. Will go look at the Harley switches and maybe reorder and go with them.

 

Well round 3 is a bust. This time I ordered 3800447 housings and 380-405 switches from JPC and they are incorrect. The right side housings will not fit with the brake lever. Below are pictures of old and new. I need help! The throttle cables are threaded so that should mean at pre-96 model. Does anyone know what I might need to order?

Old upper housing

old lower housing you can see where the mounting screw broke

old housing

old housing