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Extended bar wiring problems!

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Old Sep 14, 2023 | 06:14 PM
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From: ky
Default Extended bar wiring problems!

I’m going to look after I post BUT i just installed a a bigger handlebar and wired everything up. Testing before i button everything up and my
left turn signal dont work.
Cruise control doesn’t light up ( it wasn’t working prior but still lit up at the switch lol)
brake light on handle bar clicks at the fuse but seems to work in reverse. Foot brake doesn’t respond at all.
and horn doesnt work.
i tried googling wire diagram for the 4 deutch connectors simplified but just get the full expanded wire diagram that i have in my service manual already.

2003 road king classic*
 
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Old Sep 14, 2023 | 06:22 PM
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Well it's gonna require you go back through reck everything.
This kinda stuff comes up here a good bit. It's flat tuff when things go side ways.
First place to ck is in the L&R controls , that a tight place to put all back in.
How did you extend the wires or did ya

WP
 
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Old Sep 14, 2023 | 07:11 PM
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Originally Posted by Chunk_Norris859
I’m going to look after I post BUT i just installed a a bigger handlebar and wired everything up. Testing before i button everything up and my
left turn signal dont work.
Cruise control doesn’t light up ( it wasn’t working prior but still lit up at the switch lol)
brake light on handle bar clicks at the fuse but seems to work in reverse. Foot brake doesn’t respond at all.
and horn doesnt work.
i tried googling wire diagram for the 4 deutch connectors simplified but just get the full expanded wire diagram that i have in my service manual already.

2003 road king classic*




I don’t know if I can help. This is my wiring on my 2002 Road King Classic.
May or may not be the same as your 2003.
if it is, pay attention to the orientation of the wires and the colour of the connector.
One is black and the other grey. I can try and find the picture of the smaller black connector if I need to.
Let us know if this helps.
And yes this is on my kitchen table, this is how you can find out what kind of wife you have!
 
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Old Sep 14, 2023 | 08:41 PM
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9 times out of 10 if there's this kind of ***** up it's in the switch housing somewhere. Not always, but that's where I would start.

Last one I did I rebuilt the molex connectors as well as new wiring. Lots of wires in a small space in the switch housing, and it's not hard to pinch a wire or more if you're not very careful.
 
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Old Sep 14, 2023 | 08:52 PM
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Originally Posted by LoneBone
9 times out of 10 if there's this kind of ***** up it's in the switch housing somewhere. Not always, but that's where I would start.

Last one I did I rebuilt the molex connectors as well as new wiring. Lots of wires in a small space in the switch housing, and it's not hard to pinch a wire or more if you're not very careful.
Yeah it's pretty busy in there. I deal with wiring a LOT and there are all kinds of things during reassemble that can make you go back in.
 
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Old Sep 14, 2023 | 08:58 PM
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The wire extensions are at the connectors, right? Sound to me like you’ve plugged some in incorrectly.
 
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Old Sep 14, 2023 | 09:28 PM
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From: ky
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I upgraded to 14 inch apes with a burley wire kit. I reckon I’m going to start over and retrace my steps. One thing i can think of that may of happened is some of the connections slid out that may not have been heat shrunk good enough and pulled loose when pulling thru the bar.
start , ignition, right signal, work which leads me to believe its the other side has the issue minus the brake light.
The hand lever button works opposite. Pressed it glows softer and unpressed shines brighter 🤷‍♂️

lol here’s to a fun weekend!!
 
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Old Sep 14, 2023 | 09:53 PM
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If it was working before you touched it, then you need to redo it.
 
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Old Sep 14, 2023 | 10:04 PM
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People jack up bar extensions all the time by thinking it’s an easy job.
Did you stagger the joints to prevent a giant lump of connections being in the same spot?
Did you solder them, or splice them with a connector?

Three things can guarantee a failure:
1- Crossing wires.
This makes 2 different circuits not work.
2- Broken connections.
This can impact any or all of the wires that were extended.
3- Shorting out to the inside of the bars (ground).
This often happens when the connections are not heat shrinked, or burrs and sharp points are not filed down smooth; they end up poking through the tape and/or heat shrink and can cause all kinds of issues.

You’ve probably got little choice but to pull it all out and inspect the connections.
 
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Old Sep 15, 2023 | 07:00 AM
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When I did mine last it was my fault, pin wasn’t set in properly. Redid and voila
 
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