virgin handle bar install
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Joined: Apr 2012
Posts: 86
Likes: 0
From: Texas
Go slowly. Grips and switches will slide off the bars easily, just remove the plate holding the bars in place first then slide off the right side followed by the left. Reinstall the same way your remove the controls
Cruiser
Joined: May 2012
Posts: 156
Likes: 1
From: Space
Road Master
Joined: Nov 2011
Posts: 988
Likes: 8
From: Clinton IA
This...
It doesn't take much of a shim, but you need to clear the brake light switch. I use a zip tie folder over onto itself a couple times. Put it in when you first start, and take it out last.
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reviving an old thread here... but can you expound on this... im about to do the same thing but don't understand why this is important.
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Joined: Jul 2007
Posts: 4,007
Likes: 126
From: Manassas, VA
Maybe this'll help:
http://www.harley-davidson.com/en_US...ts/-J00445.pdf
The plunger for the brake switch is inside the switch housing, circled in red, below. The plunger is a tiny piece of plastic, prone to breakage. Installing a shim takes the pressure off the plunger so it doesn't get broken during assembly/dis-assembly. I prefer to put a rubber band or zip-tie around the hand grip, pulling the brake lever towards the hand grip. This relieves the pressure (instead of a shim) and I don't worry about it falling out or forgetting to put it back during re-assembly.
The normal position for the switch is pushed in via a tip manufactured into the brake lever. When you squeeze the brake lever, the switch is released, making the brake light illuminate.
A 2005:
Another pic, the OL's 2004, the plunger (with a tiny rubber boot over it) and lever tip circled in red. I had to squeeze the lever slightly to get this shot:
http://www.harley-davidson.com/en_US...ts/-J00445.pdf
The plunger for the brake switch is inside the switch housing, circled in red, below. The plunger is a tiny piece of plastic, prone to breakage. Installing a shim takes the pressure off the plunger so it doesn't get broken during assembly/dis-assembly. I prefer to put a rubber band or zip-tie around the hand grip, pulling the brake lever towards the hand grip. This relieves the pressure (instead of a shim) and I don't worry about it falling out or forgetting to put it back during re-assembly.
The normal position for the switch is pushed in via a tip manufactured into the brake lever. When you squeeze the brake lever, the switch is released, making the brake light illuminate.
A 2005:
Another pic, the OL's 2004, the plunger (with a tiny rubber boot over it) and lever tip circled in red. I had to squeeze the lever slightly to get this shot:
Last edited by HarleyScuba; May 26, 2014 at 09:42 PM. Reason: nunya
