I installed 18" apes last year and purchased the wiring extension with the pins already on the end so in theory, I should have been able to pull the old pins out of the connector and throw the new ones in and rock and roll. I couldnt get the old connector apart so I ended up just soldering in the extension on both ends. It is warming up again and I would like to do it right. How did you guys split the old connector? Is there a aftermarket connector that is easier to take apart? Also, what is the deal with the line that runs underneath the tank? Is that a crossover line? I didnt take off my tank last time and I believe it is part of the reason I couldnt get that rubber piece back on. Did you just cut that line? What is it called? How is it connected? Just pressed on?

 

After you get that wire stopper out of the back of the plug there should be 2 slots on the inside if you take 2 really small screw drivers or something similar on each side and push the piece out that holds the pins in place, hopefully that made sense.

 

I had the same issue with the wires. Couldn't get the dam things out for the life of me. So I ended up soldering them.

Your best bet is to ride your bike around to get a lot of the fuel out so less will spill. Because its gonna. The "crossover line" has fuel in it. I'm not sure exactly how it works but disconnecting it is pretty simple. To disconnect it get a pair of needle nose pliers or pinch/lock pliers and get the special clamp off. Then you have to use a little elbow grease to get the hose off because theres a good 3/4" nipple where the hose is one. Just work it back and forth. If you have a full tank (which I had) get a few hose clamps that will fit over the crossover hose, a extra 5/16" hose, and two bolts that fit nice and snug inside the hose to stop the gas from leaking out. Take one bolt and put it inside the extra hose along with a clamp over the hose/bolt and cinch it down. This will be used to plug up the side where you disconnect the hose from. The other bolt and clamp will go on the crossover line to block that side from gas coming out. Make sure both sides are tightly cinched down because gas will dribble out from the bolt if it isn't.

Or you could always plug up one side and drain out the other side with a long 5/16" hose into a gas can.

Hope this helps

 

Thanks,
That helps alot. I my instructions that came with it said to try and unlock it through the front and then push the wires out the back. Can you reuse the clamp to the crossover when your done?

Joe

 

They are the crimp clamps, just get some small hose clamps from autozone. I found a youtube video of a guy taking the connectors apart, helped me a ton.

 

See if this helps you out.
Or this one.
Last one.

 

If you soldered and used heat shrink you DID do it the right way. I ran the wires inside the bars and soldered the extensions in. A solder joint will be many times more reliable than any push together connector.

 

No prob.