internal handle bar wires?
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internal handle bar wires?
I got some new bars that are drilled for internal wiring (04 flhtc) and was thinking it would best to pull the wires apart at the 12 pin deutsch plug vs the handle switch assemblies, right wrong or indifferent? any pointers? Klockwerk ergo bars.
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From: ID Ho
That would be correct! They are permenantly attached on the switch end.
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From: Vermont
As for pointers, I take a needlenose pliers and "pop" up the center lock on the locking plate of the connector. Then I made a pin tool out of a very small screwdriver instead of using a paper clip. Pop the tool or paper clip in the hole to release the pin and pull from the rear. Make sure you label all the wires and draw a color chart diagram before you pull anything apart.
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Joined: Feb 2007
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From: Sedona, Arizona
Yes, I'd say that would be best to pull them apart at the plug. However you also might want to consider adding additional wire length as running the wires through the bars might make the original wires to tightly stretched, depending on the stats of your new handlebars. At least that was the case with my 07 RK. I know there is a wiring loom with all connectors in place available as an add on for this procedure and I think it is Kuryakyn that offers it.
Finally, messing with the pins can be a pain if you haven't done it before. Again, it was for me and the RK. I'm not sure if the same connectors are on your bike. If so, I'd go to the dealer and get some similar fittings as on your bike and also locate the right tools and do some practicing to avoid messing up the original wiring. The parts are not expensive, so you also might want to have some extras on hand. Once you do some practice it shouldn't be a problem. There are lots of little tips around, like using talcum powder to help pull the wires through the bars, if you do a search on this process.
Finally, messing with the pins can be a pain if you haven't done it before. Again, it was for me and the RK. I'm not sure if the same connectors are on your bike. If so, I'd go to the dealer and get some similar fittings as on your bike and also locate the right tools and do some practicing to avoid messing up the original wiring. The parts are not expensive, so you also might want to have some extras on hand. Once you do some practice it shouldn't be a problem. There are lots of little tips around, like using talcum powder to help pull the wires through the bars, if you do a search on this process.
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Joined: Apr 2006
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From: Roswell, GA
Dawg's information is for the '07 and newer bikes that have a Molex connector instead of the Deutsch connector on your bike.
Use a small flat blade screwdriver to pry off the orange "secondary lock" and use a pick tool or similar tool to slightly pry the retaining clip on the interior of the connector from a wire while pulling the wire out of the connector. I say "slightly" pry, because you will break them if you pry the clip too far from the wire.
The Deutsch connector wire locations are numbered 1-12 (very small embossed numbers on the connector), but they wrap around the connector: wire location 1 is above wire connector 12; number 6 is above number 7. When you reassemble the connector, its wire colors should correspond to those in the mating connector. Also, orientation of the "tang" on the wire socket is important for the wire to lock in the connector when you reassemble the connector. You'll hear/feel a click when the socket engages the lock.
The HD Service Manual has a good explanation with pictures on assembling/disassembling Deutsch connectors.
Use a small flat blade screwdriver to pry off the orange "secondary lock" and use a pick tool or similar tool to slightly pry the retaining clip on the interior of the connector from a wire while pulling the wire out of the connector. I say "slightly" pry, because you will break them if you pry the clip too far from the wire.
The Deutsch connector wire locations are numbered 1-12 (very small embossed numbers on the connector), but they wrap around the connector: wire location 1 is above wire connector 12; number 6 is above number 7. When you reassemble the connector, its wire colors should correspond to those in the mating connector. Also, orientation of the "tang" on the wire socket is important for the wire to lock in the connector when you reassemble the connector. You'll hear/feel a click when the socket engages the lock.
The HD Service Manual has a good explanation with pictures on assembling/disassembling Deutsch connectors.
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Joined: Sep 2005
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From: Prescott, AZ
I have an 04 and I have done this several times, very easy job and I have had several bars on my bike and never needed to extend the wires... I would STRONGLY suggests you get a service manual - in the back is the wiring diagrams - it has all the wires and colors and numbers as talked about above.. PM me if you like and I can talk you through it - once you get the plug in your hand... I promise you, once you do it - you will see just how easy it is and its even easier to put back together.... like I said, pm me and i will help all I can.
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From: Vermont
Oops overlooked the year of bike in the post
HP is correct on the deutsch
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Road Warrior
Joined: Dec 2008
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From: Mid West
Just extended mine for a set of Wild Ones, to keep tension down will be best to solder connect the leads where the extension harnesses would connect. HD extensions plug in at the OE connection and add appropriate length for longer bars but the OE connectors wind up sucked up tight to the center drilling.
'03 Anniv. RK, DCC fairing, Mustang 2Pc, Monsters with Fuel Pak, RKII bars
'03 Anniv. RK, DCC fairing, Mustang 2Pc, Monsters with Fuel Pak, RKII bars
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okay thanks for the tips. I put them on today, very easy. I love those deutsch connectors very easy to work with. had plenty of wire length with lots of slack. first side much easier threading the wire thru just because more room at the bottom hole but even the second side was not bad.
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