Hello HDF Members,

Bike: 2007 Heritage Classic
Bars: Harley Davidson Beach Bar Kit
Extra's: Nams custom 4" wire harness extension & Neoprene riser bushing kit

Question:

I am preparing to install the beach bar kit and the kit comes w/ a braided brake line. When I purchased my bike I had the dealer replace the brake, clutch and throttle cables to the braided style. Since the throttle and brake line are on the right hand control and are at a length sufficient enough for operation, I am not sure why the kit would not come w/ a throttle cable as well.

1. Will I need to replace the brake line?
2. Will I need to remove the dash panel to remove the tank?
3. Any tips to make the job easier?

Any help would be appreciated.

 

1. Will I need to replace the brake line? I would say measure the lines and check the angle of the bango. or you could look on HD website and see if your part number and the stock part number are the same length. for my 06 they were. so I did not replace.
2. Will I need to remove the dash panel to remove the tank? yes
3. Any tips to make the job easier? drain all the gas you can before removing the cross over line. first thing you do is remove the main fuel line. it has a pressure fitting like an air hose, or else it will break.

Any help would be appreciated

 

Do the wire extensions have new pin-plugs on the end? Or are they just pieces of wire. The reason I ask is because if they are just pieces of wire, you may be able to spare yourself the agony of disassembling the molex-style connectors (under the gas tank) that house all of the electrical connections. I'm gonna suggest that if you DO have to disassemble those connectors, go buy a dental pic or something really thin and strong, because it can be tedious work initially trying to figure out how they come apart, but once you figure it out, it's pretty easy. I'm gonna go search a few old threads that I posted some tips on, and see if I can attach the links on here for you. Standby.......


I have a few posts on this thread, with pics.... mind you, my bars are Narrow Beach Bars. Hope it helps a bit with what you are tring to visualize when your tank is off. Have a look...... https://www.hdforums.com/forum/softa...ag-bars-3.html


I'll go look for any more.



Ahhhhhh, this one should help you too........... https://www.hdforums.com/forum/softa...ecth-help.html








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Thanks TBL & JR.

I have the pre-configured NAMS wire extension kit. I am in the automotive parts business and have all of the tools that I will need. I am thinking of designing an extension harness with the plug connector at one end already installed, then all that would be necessary is to disassemble the other end of the connector on the bar side and connect the wires.

I wanted to try and get this done without removing the tank. Is there a way that I can just scoot the tank back without disconnecting the fuel lines?

 

Drag makes a wire set up that all ready has male and female ends on them,its a plug and play,all ya need to do is cover the ends with shrink tubeing then run em thru the bars,put pins back in molex and plug in,just remember were the wires go back in.
Took me about 1.5 hours from start to finish.....
P.S Ive been in the parts biz for 26 yrs........Good luck.

 

you can slide the tank back far enough to reach the connectors, on an 06. thus, you can leave the crossover line connected and not drain the tank. what ever you do disconnect the main fuel line. it will break if you move the tank with it hooked up. guess how I know they cost 45 dollars to replace.
I wish, twice now, I would of used a connector were I cut the signal wires.
I have a front fender cover and tank cover. I would advise covering both, just in case.
if you do mess with brake line make sure you know what type of fluid you have in the system. it says on the cover. I have dot 5 in the front and dot 4 in the rear. in your job I am sure you know dot 4 and dot 5 do not mix. and dot 4 will remove paint.
when you are getting done check your throttle, to make sure it returns. before you start zip tying everything. some people seem to have issues with the inside dragging were others the cable bind a bit.
good luck. if you any direct questions feel free to PM me I will send my number and you can call. I will be replacing the bolts on my front caliper and primary today. I do not work fast so it wont bother me.

 

Thanks for the advice. I have the old bars off now and have removed the stock rubber riser bushings.

I am taking it slow. Had to remove the headlight to get to the riser bolts.

 

This will also aid in visually looking for any binding cables/wires upon reassembly. When I installed my bars, the last thing I did was put the headlight back on. Have fun!!!!

 

Hmm didnt have to remove the headlight on the 06 Deluxe,guess I lucked out...

 

Does anybody have a snapshot from the repair manual for Softails: Fuel Tank Partial Removal?


I am at the point in the install where I need to get at the connectors for the controls which are under the tank.

I appreciate it.