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Handlebar replacement prep/tips

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Old Jan 5, 2017 | 09:50 AM
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Default Handlebar replacement prep/tips

Ordered up some Carlini 14" gangster apes in 1.25" for my 08 softail deluxe. I'm pretty new to Harleys, just bought the bike a couple months ago and this will be my first little project.

I ordered the bars, new risers, grips and extended wires so far. Should have everything next week. I figure I'll mock up the bars and measure what I need for cables.

I have all the basic hand tools, and a soldering gun, but I'm just looking for some tips or things to look out for for a noob like myself. I'm pretty good with my hands, I've been an hvac tech for 12 years now so I know my way around tools and wiring.

​​​​​I'm completely against anyone else working on any of my stuff as long as I think I'm capable. The best way to learn is to tear things apart and figure it out.

So tell me what you botched up or ran into on your handlebar install.

Thanks in advance. -Matt
 
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Old Jan 5, 2017 | 10:56 AM
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I did mine a few months back.same size Just different 18in bars. I attempted to cut and soldier the wires back together at the neck. I failed. I just recently ordered a new wiring kit to redo it correctly. Good luck and enjoy
 
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Old Jan 5, 2017 | 11:23 AM
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cover the gas tank and everything else you don't want scratched well. An ounce of prevention.

Remember, those bars can and will swing and fall as long as your longest cable/wire/brake line, etc...
 
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Old Jan 5, 2017 | 11:31 AM
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When you're having trouble tugging the wiring through the bars, rubbing alcohol makes a good lubricant that will dry without a trace.
 
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Old Jan 5, 2017 | 02:51 PM
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Make sure you have a set of poly bushings on hand to replace the stock rubber ones.
 
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Old Jan 5, 2017 | 03:23 PM
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As above....you will definitely want to replace the stock riser bushings with Polyurethane ones.
 
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Old Jan 5, 2017 | 03:38 PM
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+2 on the bushings. I would recommend getting the Harley ones listed here: http://www.harley-davidson.com/store...riser-bushings

I went with Alloy Art for mine and the steel tubes that go through the center were too long preventing things from getting tightened down properly. That made for a bit of extra work grinding them down to size.
 
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Old Jan 5, 2017 | 04:46 PM
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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.
 

Last edited by Mabbott; Jan 5, 2017 at 04:56 PM.
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Old Jan 5, 2017 | 05:26 PM
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I didn't have to remove my tank. I was able to scoot it back far enough to reach everything with the crossover hose still attached.
 
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Old Jan 5, 2017 | 05:44 PM
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Originally Posted by Mother
I didn't have to remove my tank. I was able to scoot it back far enough to reach everything with the crossover hose still attached.
Well that's good to hear. Did you just loosen the tank and push it back? Removing the tank was the only the only thing I wasn't looking forward to. Where did you splice your wires?
 
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