HandleBar Internal Wiring
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HandleBar Internal Wiring
Going to be changing handlebars this week. The old ones are internally wired and I'll be doing the same with the new.
I bought the Harley service manual thinking there would be info about running the wiring, but there doesn't seem to be anything except showing the connections for the hand controls in the headlight nacelle.
My question for someone who has done this before is, do you have to remove the wires from the connectors to get them to fit down the bars or is there some other connector or something that fits? Any help would be appreciated. If there is a place on the web showing detailed directionsthat would be great.
I bought the Harley service manual thinking there would be info about running the wiring, but there doesn't seem to be anything except showing the connections for the hand controls in the headlight nacelle.
My question for someone who has done this before is, do you have to remove the wires from the connectors to get them to fit down the bars or is there some other connector or something that fits? Any help would be appreciated. If there is a place on the web showing detailed directionsthat would be great.
Cruiser
Joined: Feb 2006
Posts: 121
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From: Atlantic City Area
RE: HandleBar Internal Wiring
I just went through extending my wiring this weekend for my new Wild1 Chubby 508's for my RKC. I found this pdf file to be extremely helpful, especially when it came to the plugs and wire colors etc.
http://mysite.wanadoo-members.co.uk/hhog/rkbarswap.pdf
It was a rather simple job and I soldered and heatshrinked all connections. Just took a bit of time and patience. Good luck.
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http://mysite.wanadoo-members.co.uk/hhog/rkbarswap.pdf
It was a rather simple job and I soldered and heatshrinked all connections. Just took a bit of time and patience. Good luck.
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Banned
Joined: Jan 2006
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From: Los Angeles, CA
RE: HandleBar Internal Wiring
Real quick. Remove tank bolts and slide tank back to gain access to wiring harness. Unplug harness. Take apart wring connector and make a diagram of how to put it b ack together. Then open your switch housings. I'm sure that other post has the rest, if not, feel free to pm me...
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RE: HandleBar Internal Wiring
ORIGINAL: anubisss
Real quick. Remove tank bolts and slide tank back to gain access to wiring harness. Unplug harness. Take apart wring connector and make a diagram of how to put it b ack together. Then open your switch housings. I'm sure that other post has the rest, if not, feel free to pm me...
Real quick. Remove tank bolts and slide tank back to gain access to wiring harness. Unplug harness. Take apart wring connector and make a diagram of how to put it b ack together. Then open your switch housings. I'm sure that other post has the rest, if not, feel free to pm me...
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RE: HandleBar Internal Wiring
Thanks ACRoadKing, those are great directions.
I'm thinking I can change the bars with removing the throttle cables and clutch cable from the switch housings. Of course I won't be able to bring the bars over to the workbench then.
Did you remove the headlight nacelle, is that necessary to get to the wiring harnesses?
Thanks to all who replied!
I'm thinking I can change the bars with removing the throttle cables and clutch cable from the switch housings. Of course I won't be able to bring the bars over to the workbench then.
Did you remove the headlight nacelle, is that necessary to get to the wiring harnesses?
Thanks to all who replied!
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Road Captain
Joined: May 2006
Posts: 554
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From: Citizen of the Republic of Texas, now in GA
RE: HandleBar Internal Wiring
The link that ACRoadKing gave you is a very good article. You should also have a service manual available. There are some good tips on the Wild 1 site - one-piece handlebar clamp & don't use poly bushings. I put 10" apes on my RKC and when I lengthened the wiring, I went ahead and put about 7" additional kength on. It is a lot easier to deal with a couple of inches extra than to wind up just a little short. Dont' for get to stagger your solders.
Administrator Emeritus
Joined: Jan 2005
Posts: 5,704
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From: Walker Basin, CA
RE: HandleBar Internal Wiring
Here is a link to replacing handlebars on a RK, complete with illustrations.
http://www.moccsplace.com/images/harley/hbar/hbar.htm
Hope this helps.
http://www.moccsplace.com/images/harley/hbar/hbar.htm
Hope this helps.