Beachbar Wiring on '92 Fatboy
The wiring plugs are too large to fit inside the bars, but if the wiring is long enough, you should be able to remove each individual wiring pin from the plug (after carefully noting which wire goes in which location), run your wires through the bars, and then re-install the pins in the plug.
First of all,its an install ofWild1 550 Chubby Beach-Bars ona '92 Fatboy.
1) Drain and remove r/h tank. Plug lines to opposite tank.
2) Disconnect 2 plugs that connect to to the old bars. Carefuly mark or diagram the wire layout to the plugs. Look at the face of the plug ,you should find a spare pin to practice removing (a blank pin with no wires conneced to it). As you look at the face of the plug, there is a small tang on the tip. Behind this is a lock that prevents the pin from coming out the backside of the plug unless depressed. Depress this and push the pin out the backside of the plug with some kind of a pushing tool (I used a small allen wrench). Once you have mastered this, remove the pins/wires making sure you can reinstall them back where they belong. You'll see the locking mechanism once the pin is removed. Just make sure its not deformed before you reinstall. Practice on the spare pin first. If you screw it up -no worries as there are no wires connected to it.
3) Once you have removed the plugs from the ends of the wires, the harness is easily pushed through the inside of the bars and carefully picked out with needle-nose pliers from the center of the new bars. It helps to have your bud there to hold the bars upside-down while you push them through. I had just enough wire to reinstall. An inch shorter and I'd spliced them. Tie-wrap the wires back together as they were before and plug them back in.
I'm not saying this is the perfect or only method. I work on aircraft and the methods there is tokeep splices to a minimum for vibration reasons (not that Harleys vibrate or anything like that, lol). This isn't that difficult by the way as long as you still have decent eyesight. Good luck -will post pics when I get time.
By the way, its like a new bike now with the new bars. Like riding a barcalounger! Good Luck...
-Frank (Just a little Northeast of Houston,Tx.)
Can't wait. Thanks for the info man,.... Damn, when I read posts like this, I'm so glad i joined this forum.
Post some pics when you get the chance. Vonzipper has exactly the same bars and his deluxe looks unreal.




