Help... wiring through handlebars
Thread Starter
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Intermediate
Joined: Jul 2007
Posts: 43
Likes: 0
From: Washington, D. C.
Help... wiring through handlebars
I need some help... 2007 FLHRC. I purchased the Reduced Reach Handlebar Kit (56152-04A). Believe I found a discrepancy in the HD instructions that occurs at a critical juncture in the process:
The task at hand is to route the handlebar control wiring from, and through the handlebars to the harness connectors inside the headlamp nacelle. The kit instructions and the shop manual are spot-on and very helpful up to the point about how to remove the wires from the MOLEX connectors. When you disconnect the halves of the connectors, the pin housing side is on the side that has to be routed through the handlebar. It doesn’t fit. The instructions specifically say: “DO NOT remove the wires from the Molex… handlebar switch connector pin housings[/b] inside the nacelle”, and also says: “Remove the wires from the socket housings.” This does not make sense. You still have to get the pin housing side off somehow or the wires don’t fit through the handlebar. To complicate matters, the instructions say “Refer to MOLEX … ELECTRICAL CONNECTORS in the Service Manual for terminal removal and…” Well, the manual describes removing wires from the socket housing very well (with special tools the handlebar instructions don’t mention), but doesn’t describe removing wires from the pin housing side. Again, the pin housing is what won’t fit through the handlebars- that has to come off. So, I’m stuck. Any ideas how to route these wires through the right way? I realize I could cut and splice the wires, but this is now a puzzle that must be solved. Please advise.
By the way, my local dealer, East Coast Harley, was no help whatsoever. I brought the manual, instructions, left handlebar switch housing, and pictures down to discuss with Service Dept folks, and they didn’t have a clue. They also didn’t exert any energy in trying to find an answer or communicate anything intelligible to me. After several awkward moments all they could offer me was “bring it down- we’ll be glad to do it for you”. So, I’m on my own, never to return to my dealer again. Any advice would be greatly appreciated- I was really hoping to hit the road this weekend!
The task at hand is to route the handlebar control wiring from, and through the handlebars to the harness connectors inside the headlamp nacelle. The kit instructions and the shop manual are spot-on and very helpful up to the point about how to remove the wires from the MOLEX connectors. When you disconnect the halves of the connectors, the pin housing side is on the side that has to be routed through the handlebar. It doesn’t fit. The instructions specifically say: “DO NOT remove the wires from the Molex… handlebar switch connector pin housings[/b] inside the nacelle”, and also says: “Remove the wires from the socket housings.” This does not make sense. You still have to get the pin housing side off somehow or the wires don’t fit through the handlebar. To complicate matters, the instructions say “Refer to MOLEX … ELECTRICAL CONNECTORS in the Service Manual for terminal removal and…” Well, the manual describes removing wires from the socket housing very well (with special tools the handlebar instructions don’t mention), but doesn’t describe removing wires from the pin housing side. Again, the pin housing is what won’t fit through the handlebars- that has to come off. So, I’m stuck. Any ideas how to route these wires through the right way? I realize I could cut and splice the wires, but this is now a puzzle that must be solved. Please advise.
By the way, my local dealer, East Coast Harley, was no help whatsoever. I brought the manual, instructions, left handlebar switch housing, and pictures down to discuss with Service Dept folks, and they didn’t have a clue. They also didn’t exert any energy in trying to find an answer or communicate anything intelligible to me. After several awkward moments all they could offer me was “bring it down- we’ll be glad to do it for you”. So, I’m on my own, never to return to my dealer again. Any advice would be greatly appreciated- I was really hoping to hit the road this weekend!
Road Warrior
Joined: Jan 2007
Posts: 1,779
Likes: 223
From: Northern California
RE: Help... wiring through handlebars
Stop!! Don't cut nuttin! I just did this and as ussual, it's a piece of cake. You need to remove the pin's from the housing that goes to the handlebar switches so that you can run the wires thru the bar's. No biggie. This is how you do it. Look down the housing between the pin's and you'll see the secondary locking plate. in the center of it you'll see two oval slots. You need to pry up on that (small needle nose or what I used was a curved dental pik) pry it up half way, this releases the pins. then install a paper clip or bobby pin into each hole beside the pin and wiggle it until you can pull the pin out from the rear. there is a little locking tab in there, once you get the first one (will be a bitch) you'll know what to do with the rest. Of coarse write down a diagram so that you can reinstall them correctly. Any problems throw out a shout, good luck, Putt
Tourer
Joined: Mar 2007
Posts: 463
Likes: 0
From:
RE: Help... wiring through handlebars
Yup...you disassemble the connectors, then run the wires down the bars, then reroute them and re-assemble the connectors.
Not tough once you figure out how the things are actually disassembled.
Not tough once you figure out how the things are actually disassembled.
Elite HDF Member
Joined: Oct 2006
Posts: 4,602
Likes: 5
From: Southern California - Palm Springs Area
RE: Help... wiring through handlebars
Yep... Write the pin connectors down on paper & take a picture (digital) if you have one... Use a Silicone Spray or a light oil on the wires your running as it will make it easier to push\pull
Seasoned HDF Member
Joined: Sep 2005
Posts: 5,072
Likes: 104
From: Prescott, AZ
RE: Help... wiring through handlebars
So easy a cave man can do it.... if you still have troubel... pm me and I will give you my cell number, I can walk you though this in my sleep - I could not decide on what bars to install - my garage looks like a parts house for bars... Wild1 loves me....
Thread Starter
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Intermediate
Joined: Jul 2007
Posts: 43
Likes: 0
From: Washington, D. C.
RE: Help... wiring through handlebars
You guys rock! So what you're telling me is the HD instructions are WRONG. You DO disconnect at the pin housing. That's what I thought, but being of engineering-mind myself, I couldn't break from 'the directions'. I'll pull the pin side of the Molex connectors apart tomorrow. Then will let HD know their instructions are off.
Thanks. Will be crusing by mid-day...
Thanks. Will be crusing by mid-day...
Road Master
Joined: Jun 2006
Posts: 1,220
Likes: 2
From: iowa
RE: Help... wiring through handlebars
Hey SMac,
Check out this link , if you scoll down a bit there are some very detailed photos. Hope it helps.
https://www.hdforums.com/m_1328001/tm.htm
Jeff
Check out this link , if you scoll down a bit there are some very detailed photos. Hope it helps.
https://www.hdforums.com/m_1328001/tm.htm
Jeff
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Tourer
Joined: Mar 2007
Posts: 463
Likes: 0
From:
RE: Help... wiring through handlebars
Regarding MoCo "Instructions", search on the detachable kits...they are *legendary* and most commonly thrown away as the best 1st step.
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Thread Starter
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Intermediate
Joined: Jul 2007
Posts: 43
Likes: 0
From: Washington, D. C.
RE: Help... wiring through handlebars
Finally finished! Thanks to all who offered advice, it was a big help. I have some lessons learned:
Anyone putting reduced-reachbars on their FLHRC better be prepared for a fight with the wires. The wires really aren't long enough for the new bars (despite the HD guidance that they are). Getting the wire housings in an acceptable place with, like, 1 inch of wire to play with is a rubics cube-like puzzle. Reference the picture... can you believe? Anyway, I found a way to get it done,and went riding today... nice!
Anyway, thanks again
Anyone putting reduced-reachbars on their FLHRC better be prepared for a fight with the wires. The wires really aren't long enough for the new bars (despite the HD guidance that they are). Getting the wire housings in an acceptable place with, like, 1 inch of wire to play with is a rubics cube-like puzzle. Reference the picture... can you believe? Anyway, I found a way to get it done,and went riding today... nice!
Anyway, thanks again