Handlebar changing--advice needed
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Cruiser
Joined: Mar 2014
Posts: 118
Likes: 5
From: Pennsylvania
Handlebar changing--advice needed
Is it hard to change out the handlebars on a harley with internal wiring? I have a '13 dyna street bob and am switching to a slightly different style bar, same height. Anybody have any advice or tips for dealing with disconnecting the internal wires (preferably without cutting anything)? Some detailed instructions and/or pictures would be awesome. Thanks in advance for any suggestions!
Elite HDF Member
Joined: Sep 2008
Posts: 4,440
Likes: 148
From: Northwest
#1. Get a service manual... it explains how to unpopulate wiring connectors, and if you're doing internal wiring, you'll have to do that.
There are also going to be a crap load of threads on the site here, that go into this... do a little searching to find them.
Other than that: depends on if the bars you're going to are taller/wider, that will need longer wiring. Some 'kits' are available. When I did mine, I added 8" to the wiring, splicing it myself. If you're gonna add wiring, offset the splicing by 1/2" from wire to wire: that way you won't have a big bundle of splices all at the same spot, creating a big 'lump' in your wiring.
Don't be in a hurry. Take pictures and make drawings of your connectors and what color wire goes to which pin.
Do a couple of searches... there's loads of tips and tricks on this site for ya.
There are also going to be a crap load of threads on the site here, that go into this... do a little searching to find them.
Other than that: depends on if the bars you're going to are taller/wider, that will need longer wiring. Some 'kits' are available. When I did mine, I added 8" to the wiring, splicing it myself. If you're gonna add wiring, offset the splicing by 1/2" from wire to wire: that way you won't have a big bundle of splices all at the same spot, creating a big 'lump' in your wiring.
Don't be in a hurry. Take pictures and make drawings of your connectors and what color wire goes to which pin.
Do a couple of searches... there's loads of tips and tricks on this site for ya.
I just changed one of my bikes out to a longer set of bars. There is no way around cutting the wiring if the it is internal. I used this guy on youtude. He has a lot of very good instructional videos that helped me through it. Here is just one.
Intermediate
Joined: Dec 2013
Posts: 44
Likes: 0
From: Green Bay, WI
My method for getting the wires back through is to run a string through the new bars, use the string to pull mechanic's wire through, then use the wire to pull the harness through. If you're going to be a DIYer with your bike, learning how to pull apart and rebuild connectors is a very useful skill to have. Take your time, search the forum, use YouTube, and take a lot of notes with pictures.
Road Captain
Joined: Aug 2012
Posts: 658
Likes: 3
From: +^
bar swap
[QUOTE=jmerchant.1;12936552]Is it hard to change out the handlebars on a harley with internal wiring? I have a '13 dyna street bob and am switching to a slightly different style bar, same height. Anybody have any advice or tips for dealing with disconnecting the internal wires (preferably without cutting anything)? Some detailed instructions and/or pictures would be awesome. Thanks in advance for any suggestions
Novice
Joined: Jun 2014
Posts: 18
Likes: 0
From: Glendora, CA
Going to bars that are of similar size is easy. You don't have to worry about clutch, throttle, idle, and brake cables. For internal wiring, unfortunately, you will have to disconnect the wires in some way. I would just cut and splice the wires back up. You may not have to extend the wires at all, unless the new bars have a similar shape to that of a crazy straw. If you don't have much experience with type of work, I'd give myself an hour to a couple hours to do this. Someone that's done it before will probably only take fifteen minutes or so.
Good luck!
Good luck!
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Tourer
Joined: Apr 2013
Posts: 286
Likes: 0
From: Bay Area, Cali
On the '12 and up dynas running the canbus system, they have smaller connectors. No need to de-pin, or remove wires from the connectors. They will slide right through the bars. It makes the job a lot easier! As stated before if the bars are the same diameter, you will be good to go, without having to take connectors apart. Just unplug them, down by the neck, pull em through the old bars, and feed em through the new ones! Simple job.
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Thread Starter
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Cruiser
Joined: Mar 2014
Posts: 118
Likes: 5
From: Pennsylvania
Thanks guys for all the info, it was very helpful. I will take all into consideration when I give it a go in the next day or two! Anything else I may need to know feel free to share. Thanks again!!
Last edited by jmerchant.1; Jul 2, 2014 at 08:04 PM.