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FLHT Handlebar Install Help

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Old Feb 4, 2012 | 01:27 AM
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Default FLHT Handlebar Install Help
I'm swapping out the bars on my EGC and I've hit a sticking point. I figured this was a good place to take a break while I come in and ask all y'all's opinion.

I've gotten the inner fairing cap off, the radio is out, and the handlebar clamp is exposed ... but how the hell do you work around that piece of inner fairing that's right where it'll get scratched up as you take the clamp off?

My neighbors welcome your suggestions -- I'm pretty sure they're tired of listening to me cursing.

FLHT Handlebar Install Help-q9scl.jpg
 
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Old Feb 4, 2012 | 01:40 AM
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Remove the bolts on the inner fairing and you can move it out of the way without scratching anything
 
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Old Feb 4, 2012 | 10:51 AM
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Also a good time to use the newer clamp bolts (at least on top/rear) that were designed to stop making contact with the HK radio and causing CD skip problems.
 
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Old Feb 4, 2012 | 11:34 AM
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Originally Posted by z71_fourwheelin
Remove the bolts on the inner fairing and you can move it out of the way without scratching anything
Nope, not possible. Aside from the 4 bolts that hold it to the bracket, there are numerous other connections I'd have to take off to let it move, like on the fork legs. And even if I did, it still wouldn't work because the bars themselves will prevent the fairing from moving toward the rear of the bike and the fairing bracket will prevent it from moving forward.

Anyone else have any suggestions?
 
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Old Feb 4, 2012 | 12:23 PM
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When I did mine I pushed the bottom lip a little as it is flexible as long as you don't have the chrome radio trim plate on it. It allowed me to get to the two bottom bolts.
 
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Old Feb 4, 2012 | 12:41 PM
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I just changed my bars. When you unbolt the inner fairing you need to grip the bottom and pull the entire inner fairing up and off of the forks where it slide on to the bracket that the bolt holes are on, then you will be able to roll the fairing forward and access the the riser clamp. I did not even have to remove my radio.
 
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Old Feb 4, 2012 | 02:03 PM
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Um...Yes you can. I've done 10+ bikes with apes. Just like Steelerdude1 states
 
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Old Feb 4, 2012 | 02:22 PM
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This helped me alot doing WO575s on my 2005 Ultra.

http://www.kenandjudy.us/Motorcycles...new_page_1.htm
 
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Old Feb 4, 2012 | 03:52 PM
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Originally Posted by z71_fourwheelin
Um...Yes you can. I've done 10+ bikes with apes. Just like Steelerdude1 states
You're right, my apologies. I freed up the fairing as you suggested and lifted it up enough to get access to the handlebar clamp bolts.

I now have the bars off and I'm fighting with the new ones to run the wiring internally. Does anyone know how to open up this connector? Ideally I'd like to reuse the plug and not have to cut and solder anything.

FLHT Handlebar Install Help-0ja6c.jpg
FLHT Handlebar Install Help-shbyu.jpg

Edit: Nevermind, I found this video that showed how to open it up.
 
Last edited by Freeway; Feb 4, 2012 at 04:42 PM. Reason: Solved my own problem.
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Old Feb 4, 2012 | 04:09 PM
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Originally Posted by Freeway
You're right, my apologies. I freed up the fairing as you suggested and lifted it up enough to get access to the handlebar clamp bolts.

I now have the bars off and I'm fighting with the new ones to run the wiring internally. To be continued...
I didn't have TBW wires to deal with but I did have to run my heat demon wires through the bars, WOW what a trying experience. I'm not real sure what all is involved with the wires you need to pull through, but maybe this trick I found can help you. I got a string and used a shop vac to suck it through the bars, taped my wires to the string and pulled them right trough. I wish I knew about this trick, it would have save me a lot of time messing around with mechanics wire.

Good luck.
 
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