Well I started the process yesterday after discussing it for many months. I got home from work and dug right in.

Accomplished last night:
-Controls removed and tied up.
-Old bars and risers removed.
-New risers mounted and locktited.

Now the new question. Looks like I am good on all cabling sizes. I was trying to trace the wiring back from the bars last night but not having the best luck. On my 2005 Deluxe is the wiring "harness" under the tank or back at the battery area? Would it be better to take the wires from the harness and run then through the bars or removed them at the controls and run then through the bottom of the bars to the controls? Man I am so close to having this done. Going tonight and grab a wiring extension for +6 inches just to make sure if I need it I will ahve it...

Eric

 

should be 2 6-pin Deutsch plugs, 1 on each side of the frame directly underneath your tank. You'll have to remove the tank, unplug each connector, remove the secondary lock with a small flat blade screwdriver, make a note of position of wires in connectors, and depin them. You'll want to come through the control slot of the handlebars and out the bottom by the risers. The wiring inside the switch housing, last I looked, wasn't capable of being removed. If you need the wire extension, just solder it inline with the current cable so that you don't have to recrimp pins. I would suggest staggering your solder connections to keep a lower profile and prevent bunching up of your cable when pulling back through.

 

same as above.

 

Ok that sounds easy enough except for the part that I forgot I had Gas in the tank!!! Man I have like half a tank still. I guess I have to find a way to get that out first! I need to take today off and go work on it!!!!

 

Rather than remove the tank can't you slide it back after disconnecting the supply line and removing the bolts that hold the tank in place?

Just did new handlebars on a friend's bike, and had another buddy's stuff powder coated and was able to do this on both without draining the tanks.

 

Good luck just pay attention. Just did bars again on Sat

 

You could probably do it this way, but be sure to also disconnect the fuel gauge connector. It would still be easier to fully remove the tank but there is no real good way to drain it completely if you're removing the crossover hose in the front. I thought I had mine bone dry and I still sprayed gas all over the place getting it off

 

If your bike is EFI when you disconnect the fuel line it won't leak out of that fitting. The cross-over I just took a bolt and stuck it in the hose. Tight enough to have to kinda thread it in and the opposing side I put a rubber nipple on that side of the tank (Can get a pack of multi-size at your local auto parts or hardware store) and I spilled a very minimal portion of gas, little splash that was about it. As far as pulling the tank if your wiring harness is where mine is under the tank up closer to the front of the frame I don't see how you'd get away with not pulling the tank off. Your cross-over would have to be disconnected to lift it up anyhow so seems silly to fumble with it in the way when it's just two bolts from sliding off at that point. Good luck with the install!

 

I removed my tank. I found it much easier and safer for my paint. It also allowed cleaning of the rocker boxes.


Good Luck

 

Well today to took off from work early to get some work done on the bike. Was going to grab the wiring extensions from the dealership on the way home. They don't carry them and have to order them. Figured I would press my luck.

Got home and took all my new toys out to the bike. Got my new downtube chrome covers, chrome neck covers, chrome triple tree bottom cover, SE gasket kit to repair my heavy breather gaskets, and new vance and hines tuner came in.

Got started on the bike. Removed all the gas out of the tank. Removed the main line in the back and all the screws holding it on the bike. I just slide the tank back and exposed the wiring harness. I removed the left side harness and carefully diagramed the wiring in the harness. Placed the new bars on the bike and ran the wiring internally. I found out that I do Ned the extension. All but 2 of those wires reached but I wasn't going to pull them tight. I will just get the wires later. Placed the old bars on the new risers to find the triple trees seems to be bent somehow :-(. One riser is higher than the other with both the old and new risers installed. Oh we'll rode it this way now for 5,000 miles and this isn't going to stop me. Tomorrow is finally reassembly and cleaning for Saturdays trip to Petersburg for the Harley drags. All the chrome got added though.

Now new topic. The Harley places told me they think my bike has a download on it but not sure. There is no tuner on it and stage 1 is complete on it. If I put that vance and hines tuner on it and the download is there what can happen? I don't want to screw up the tuner or lose the download! Any thought???

Eric