1996 fatboy

I installed new handlebars.
I cut into the wiring under the handlebar by the forks. Soldered back together.
Then I realized I cannot fish the wire through the new bars so I went for external wiring.
But with the external wiring my master cylinder clamp will not screw in . I tried to tighten it best I can but then the Master cylinder clamp is cutting in to a power wire and shorting out the bike. So it seems I am forced to wire internal. Otherwise I cannot clamp down my hand controls.

So the bike is sitting here with the hand controls off. I am looking for what to do and how to do

I am guessing I need to pull tank off and rewire the whole harness up to the hand switches and go through the bar?

I would appreciate any help , I am not a super handy guy but not too bad if I can get some guidance

So where should I start?

 

If the bars aren't dimpled to allow the wires to run under the clamp you'll have to either cut a channel where the dimple would be or run them internally. When I ran mine internally I had to enlarge the channel as I had the same issue and the wires wouldn't clear the clamp.

 

You don't need to cut the wires, the deutz connectors are tucked inside the frame by the headstock, you just pull them out, dismantle the connector leaving just the pins on the wires and pull through the bars. If extending them you can get a plug and play extension kit or buy new switches with extended wiring that you cut to length and solder the pins on once the bars are installed.

 

I basically just did the same thing when I swapped my new controls/bars on my fatboy. I would suggest using a shoe string or bicycle brake line to fish through the handlebars first, then tape your wires to it and pull the wires back through.

For my application I bought all new terminal connections to put on the new wires instead of re-soldering the old ones back on.

https://www.namzcustomcycleproducts....al-connectors/

 

Is the deutz connection accessible without removing the gas tank ?

 

You mean the wires are connected to the hand switch with terminals not soldered?

 

The wires are soldered to the switches, but you have terminals in a connector in the wiring harness down by or in the frame. Some models have the terminals and connector in the wiring harness under the tank, some are in the frame (like my dyna) some are in the headlight bucket.YD

 

Ebay sells the chrome hand switches with the wires attached for 50 dollars as a set. Do you know if it is easy to replace the control switches in the housing? This way I can just replace the switch and run the wires direct to the harness and connect

 

I am stuck on getting the circlip on the brake lever bolt. I do not have circlip pliers. Any tips ?

 

Yes you can replace the switches only and not have to replace the housing that the switches fit into. However, the other end will be bare wire with no terminals so you will need new terminals and the proper crimping tool to install them properly.


Get a pair of circlip pliers. Under 10 bucks at most automotive places...OK maybe 15 Canadian. YD