Here's my 08 road king classic with stock bars
Hi everyone. I am fairly new to this site and decided to replace my stock bars with some Burly Beach Bars. I will be wiring them internally and also going to re-install my H.D heated grips also with the wiring inside the bars. I will be attaching pictures that may help others with this year and model bike. This will be my first thread and hope i am doing it right. Lopezluna

 

Not that difficult, take your time, have service manual ready, take pics, and definitely get and use wire lubricant for pulling your wires, makes life nice and easy. Good luck!

 

Thanks for the advice and motivation nutsandbolts5212.

 

Here are some pictures of the teardown process to remove my handlebars. Hopefully these pix will help someone to remove their bars or just adjust them. Make sure you cover and protect all your painted surfaces and chrome. Make sure to remove the 50 amp fuse that is on the left side cover before you go any further.


Remove fuse



Remove headlight trim



Remove headlight assembly



Headlight assembly removed



Remove lock cover with a small flathead screwdriver. There's a slot you can insert the screwdriver and pri to pop the cap off



Remove two phillips screws



Remove the nut inside that secures the spear on to the nacelle and remove the spear



Notice the end of the spear has a hook



Remove the nut and washer. (Top center )



Now remove the cap covering the handlebar clamp.



Now your handlebar clamp is exposed. If all you need is to adjust your handlebars this is it. Just loosen the bolts with a 1/4 inch allen wrench.



Remove one bolt and one nut from both sides. These hold your brackets for your passing lights.



Make sure not to loose the rubber grommets used to attach the front windshield.



Unplug the connectors from both left and right sides of nacelle. These go to the toggle switches. One controls the passing lights and the other is a aux switch



Almost forgot, i let my passing lights lay on my fender.



Remove both left and right sides of nacelle carefully pulling on them



Now this is what it looks like with the nacelle removed. You do not have to remove the nacelle but you have much more room to work with if you do. Now you can start unplugging wire harness connectors that pertain to your handlebars







Now you can apply your fron brake lever and wedge a piece of cardboard so the lever does Not go back to its regular position. This is to protect the little switch that is on your control housing from getting damaged. Now do the same for clutch side. Sorry, i forgot to take pix of this. You will need torx sizes t25 and t27 to remove the levers and switch housings. There are two screws on each (one on bottom and one on top).



Remove the 4 bolts holding the clamp with a 1/4 inch allen wrench. Remove the clamp and now you can remove the handlebars.



Handlebars removed.

 

Hope that helps someone.

 

I had the H.D heated grips on my stock bars and am going to install thembon my new bars. The grips were made to where the wires from the left grip have to be ran outside the handlebars. I am modifying mine to run the wires internally.

 

Looking good!

 

Good job!

 

Thanks guys! My bars are to be delivered any day now so i will be replacing the riser bushings meanwhile. No better time to replace the riser bushings than now. I will be taking pictures as i go.


Riser bushings will be replaced. Looking at the riser bolt.



The bushings are right under the risers

 

Made my wire diagrams
Soldered every wire
Used shrink tube
Crimped on new molex connectors and inserted back in to the connectors. I pulled all the wire harnesses inside the handlebars and tested them.
Heres a pic of the burly bars before i replaced the front brake cable.
Burly beach bars installed. These are the 38.5 width bars not the bikini bars. I was going to re-install my H.D heated grips but i would have had to bore the inside left of the bars and i chose not to.
08 road king with burly beach bars