Hey all, I also posted this in the electrical forum. I have a 2014 SGS..the issue...
I changed handle bars yesterday to 12" KST Mayhem Baggers. It is a time consuming job but I did it....for a single start anyway.
I put the bike back together with the exception of the outer fairing and I snugged the switch housings loose enough where I could still turn them for final adjustment. I started the bike, checked all the lights, switches, radio and gauges and all was perfect.
I put on the outer faring, adjusted the levers and switch housings and tightened them down. Rolled the bike out of the garage, it won't start. Radio powers up but mute is on and I can't turn it off. All gauges and dash lights do not power up, hand controls do not work, fuel pump does cycle when key is turned on. I have checked the fuse box and saw no issues, can not find any wiring issues, didn't remove bars again cuz all worked fine on first start. Thoughts? Is there a fuse somewhere I'm not aware of? Help!!

 

Those mayhem bars are awesome looking! Went with the LA choppers twin peaks myself.
seeing as it worked at first I’d back up and check for wires pinched in the housings or that all pin connectors are properly seated at the plug in the fairing. I had similar issues but was regarding the the green plug on the TBW. Separated while pulling through. Found out after re assembly!
Good luck I’m sure you’ll figure it out and those bar will look great.

 

Also ensure that your ignition key is clocked properly on re assembly. It’s easy to get that misaligned and can cause similar issues.

 

I'm not really sure what you mean here. The only thing I have is a barrel key to lock the ignition and the bags. The big ignition thing I turn to power up the bike never got moved for this job, am I missing something?

 

I guess not if you never had to touch that but how did you access the handle bar clamp without removing the dash panel? Your isn’t much different than mine. Irregardless if it never came out it isn’t your issue.

 

If the dash panel is that piece that has all those dead switch plugs, it has a bolt on each side that comes out to move it and expose the clamps.

 

Yeah just re watched kst’s video you don’t require removal of the main key column. Mine did. Issue has to be related to either pinched wires at the grip or molex pin positions at the plug. Any wire extensions used? I don’t think extensions were needed on your year and 12” bars but...

 

Yes, wire extensions were used except for the TBW. They were suggested by KST. It's almost worse that everything worked fine after installation. Put on the outer fairing, tightened up the switch housings and it's a no go. I have removed the switch housings and found nothing out of place, took off the outer fairing and uncliped and recliped everything, no luck. It's hard to imagine it's in the bars when it worked on first try. I sure don't want to pull all the wires out of the bars for no reason. I appreciate the thoughts though.

 

And it’s affecting both sides. Which made me think it may be ignition switch related. Have you been able to get it back to the point when it had worked? Like when the housings were loose? That really shouldn’t be the difference. Do you have a ground strap on your bar clamp? I know when I tilted my inner fairing* forward I unknowingly disconnected that. Doubt that would cause an issue but I’m at a loss too.
there are a Few big brain electrical guys on the forum, hopefully they will offer some insight. I understand your frustration, especially after tackling this big a job. You’ll get it figured out and remember what the dealer would have charged you for the same job....

 

The switch housings are off and dangling down now with no luck. I will ck the ground you speak of first chance I get, thanks.