Handlebar replacement prep/tips
Tourer
Joined: Nov 2016
Posts: 295
Likes: 26
From: Western CT
Loosen the tank and lift it up high enuff to get at your connectors. On the apes I've done, I always spliced inside the bars where the wires won't get exposed to the elements. Stagger your splices to reduce the overall diameter of the bundle. Make sure you use heat shrink tubes over every wire. Take your time and measure three times, cut once. Try electrical taping a flexible coat hanger to the end wire to tug everything thru. Leave the wire ends long. Go slow, you'll be fine.
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Tourer
Joined: Apr 2016
Posts: 278
Likes: 58
From: Connecticut
Another easy way to get through the bars is use small link chain.
It goes around all the bends easily with a little jiggle.
https://www.youtube.com/watch?v=EDbR7l43EVk
It goes around all the bends easily with a little jiggle.
https://www.youtube.com/watch?v=EDbR7l43EVk
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Tourer
Joined: Apr 2016
Posts: 278
Likes: 58
From: Connecticut
What went wrong? Just some bad solder joints?
Road Warrior
Joined: Nov 2011
Posts: 1,397
Likes: 403
From: Australia
Haha awesome video. Thanks man. That chain link looks like it works really well. I'll try that out. Any tips on measuring how much you need to extend the wires? Pull existing wires through, put the bars on the risers and then just measure from the end of the old wires to the plug. Add maybe an inch or two for some slack?
The ol' saying...."Better to be looking at it, than looking for it"
Make sure you use heat shrink on any/all wire joins.
Intermediate
Joined: Dec 2016
Posts: 40
Likes: 1
From: Texas
I siphoned all the gas out of my tank before removing and the only gas that spilled was what was left in the crossover fuel line, a couple of tablespoons that I basically caught in a towel.
I'm scraping the stock risers and clamp and got carlini high roller risers, do they come with new bushings? Edit: They dont, I definitely need to pick up some poly bushings. I think ill try the string and vacuum trick to pull a snake through the bars. Any advice on removing the tank? Should i try and siphon as much gas out first? Ive heard some pretty rough stories of getting gas all over the place removing the hoses. All sound advice, thanks.
Road Captain
Joined: Oct 2010
Posts: 613
Likes: 17
From: Boston, MA
[QUOTE=Mabbott;15812207]I'm scraping the stock risers and clamp and got carlini high roller risers, do they come with new bushings? Edit: They dont, I definitely need to pick up some poly bushings. I think ill try the string and vacuum trick to pull a snake through the bars. Any advice on removing the tank? Should i try and siphon as much gas out first? Ive heard some pretty rough stories of getting gas all over the place removing the hoses. All sound advice, thanks.[/QUOT
I used a small siphon pump to get the majority out and then used a flexible funnel to catch the leftover gas when I cut the crossover line. I made a thread about it:
https://www.hdforums.com/forum/softa...k-removal.html
I used a small siphon pump to get the majority out and then used a flexible funnel to catch the leftover gas when I cut the crossover line. I made a thread about it:
https://www.hdforums.com/forum/softa...k-removal.html
Cruiser
Joined: Oct 2016
Posts: 134
Likes: 12
From: Texas
The stock wires are long enough to pull through the bars. Make it easy on yourself and get some namz extensions with plugs. Super easy. There really isnt any prep work to do. But I would run a round file over the edges of every hole wires go into and come out of. I always pull the tank off. It makes getting to to the cables easier. Shouldn't be more than a 3 hour job if you use the wire extensions. Plus if you ever sell the bike and want to keep the ape set up it makes putting it back to stock much easier.
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Tourer
Joined: Apr 2016
Posts: 278
Likes: 58
From: Connecticut
Just got my bars and risers in today and damn they are bad ***. As far as loctite goes.....blue and use it on all bolts for the risers and riser bushings? Already have my wire extension, grips will be in tomorrow and new poly bushings on Thursday. I'll probably get everything on on Friday.
Tourer
Joined: Jun 2009
Posts: 466
Likes: 16
From: Montgomery,Il.
I took pics w/phone of connectors before removing pins so I knew proper placement on reassembly.WD40 is good for sliding wires through bars also.
Last edited by durtyburt; Jan 11, 2017 at 08:19 AM.