Handlebar installation
Road Captain
Joined: Mar 2007
Posts: 572
Likes: 6
From:
Check out my "how-to". It's for putting 16s on an 07 RKC, but should parallel most of what you gotta do. 
https://www.hdforums.com/forum/touring-models/271781-a-how-to-guide-for-ape-install.html
https://www.hdforums.com/forum/touring-models/271781-a-how-to-guide-for-ape-install.html
Ultimate HDF Member
Joined: Mar 2008
Posts: 5,788
Likes: 203
From: SW Florida
I recently installed a set of Khrome Werks 300515 +2 Wide Sweeper bars on my 2008 Street Glide and ran the wire internally. Here a write-up on the process, along with these pics.
The service manual came in very handy. There is a section on the different wire connections. On the Street Glide all involved connectors were the Molex type.
Once the controls are removed from the old bars move them over to a work area along with the new bars. Make note of each wire location within the connector so they go back in the correct location. I took photos along with notes. Remove the wire ends from the connectors using the instruction in the service manual. Drop a string with a nut on the end down the bars until it comes out the opening in the bottom of bars. Drop two strings down the throttle side. One for the control wires and one for the sensor wires. Tape the string to the end of the wires and gently pull them through. I removed most of the sheathing protecting the bundle of wires. I left just enough at the control end so it could be fed a little way through the top hole in the bars at the controls. The sheathing left over can be slipped over the wires coming out the bottom of the bars and fed up to help protect the wires within the bars.
On the throttle side, I decided to replace the throttle grip sensor which eliminates the green connector. This helps when pulling the wires. The end result should look something like this. I connected the throttle grip sensor wires after the bars where installed.
Wire extensions were not needed but the connectors within the fairing had to be relocated and tied down. I spent about an hour rotating the bars while watching the wires to make sure there was no wires binding.
Take you time. The results are well worth it.
The service manual came in very handy. There is a section on the different wire connections. On the Street Glide all involved connectors were the Molex type.
Once the controls are removed from the old bars move them over to a work area along with the new bars. Make note of each wire location within the connector so they go back in the correct location. I took photos along with notes. Remove the wire ends from the connectors using the instruction in the service manual. Drop a string with a nut on the end down the bars until it comes out the opening in the bottom of bars. Drop two strings down the throttle side. One for the control wires and one for the sensor wires. Tape the string to the end of the wires and gently pull them through. I removed most of the sheathing protecting the bundle of wires. I left just enough at the control end so it could be fed a little way through the top hole in the bars at the controls. The sheathing left over can be slipped over the wires coming out the bottom of the bars and fed up to help protect the wires within the bars.
On the throttle side, I decided to replace the throttle grip sensor which eliminates the green connector. This helps when pulling the wires. The end result should look something like this. I connected the throttle grip sensor wires after the bars where installed.
Wire extensions were not needed but the connectors within the fairing had to be relocated and tied down. I spent about an hour rotating the bars while watching the wires to make sure there was no wires binding.
Take you time. The results are well worth it.
Ultimate HDF Member
Joined: Mar 2008
Posts: 5,788
Likes: 203
From: SW Florida
Elite HDF Member
Joined: Jun 2006
Posts: 3,698
Likes: 11
From: Longview, Washington
Did it myself a couple months ago. No short cut I know of except for tipping the bike to avoid loosing too much trans oil.
Steve
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Ultimate HDF Member
Joined: Mar 2008
Posts: 5,788
Likes: 203
From: SW Florida
I just went out to the shop to check on this. I bought a full Brembo set-up from a forum member to replace my 07 brakes. I was hoping to use Speedbleeders on them.
Damn . . . they are not the same size. The Brembo bleeders are built into the banjo bolt and they are a smaller size. They also have an 0-ring seal on them. They take a 3/8 wrench although the threads look metric. This would make sense that HD would have them make the "nut" a standard size.
Anyone know the thread size????
I'll have to do some research. Think I'll send an email to the Speedbleeder people and see what they have to say.
Stay tuned . . .
Damn . . . they are not the same size. The Brembo bleeders are built into the banjo bolt and they are a smaller size. They also have an 0-ring seal on them. They take a 3/8 wrench although the threads look metric. This would make sense that HD would have them make the "nut" a standard size.
Anyone know the thread size????
I'll have to do some research. Think I'll send an email to the Speedbleeder people and see what they have to say.
Stay tuned . . .
Ultimate HDF Member
Joined: Mar 2008
Posts: 5,788
Likes: 203
From: SW Florida
