I swapped bars......my advice for you!
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Road Master
Joined: Sep 2011
Posts: 764
Likes: 1
From: N. Texas
I swapped bars......my advice for you!
Let me preface this with THIS WAS MY EXPERIENCE. This will be my advice to whomever cares to read it. Went from stock handlebars on my '09 SG to KW Sweepers +2(300811's). My plan was internal wiring. My plan was this taking a max of 4.5 hrs. I changed to apes on my '11 Forty-Eight. I knew it would NOT be the same due to the fairing, wiring, etc. I took everything apart while waiting for my new bars & clutch cable to arrive. After going thru the paces of removing all the wiring from both left & right 'plugs' so I could run them internally I realized it was a massive waste of time. Once the new bars arrived I soon found out I was not going to be able to wire them internally due to the TBW. The TBW gave me enough hassle that I figured there's no way for me to run the throttle side wiring inside the bars. So I 'pligged' all the wires back into their respective 'plugs' & went from there. The clutch cable arrived & I ran it thru the fairing but was having a huge gathering that night so put the fairing back on. DON'T do that!!! Words of wisdom:
1) lay clutch cable flat on ground so it can be tightened to tranny
2) put bike on 2x6's or you'll waste enough tranny fluid it won't register on dipstick(now I'm waiting on another qt. of Red Line to show up)
3) you CAN use a rope to pull clutch cable thru fairing w/out removing it
4) HD didn't supply a new o-ring for clutch so buy one!
5) take your time & love your children
Take all this w/a grain of salt. Hope this helps someone in the future!!!!!
1) lay clutch cable flat on ground so it can be tightened to tranny
2) put bike on 2x6's or you'll waste enough tranny fluid it won't register on dipstick(now I'm waiting on another qt. of Red Line to show up)
3) you CAN use a rope to pull clutch cable thru fairing w/out removing it
4) HD didn't supply a new o-ring for clutch so buy one!
5) take your time & love your children
Take all this w/a grain of salt. Hope this helps someone in the future!!!!!
Extreme HDF Member
Joined: Jun 2011
Posts: 10,216
Likes: 224
From: Glendale AZ
Yeah the TBW plug and the loose black plug poses a challenge. Many including myself just cut the green plug and spliced it. The black plug is for heated grips and I carefully sniped that line at the TBW unit. Oh and if your trying to run all that wiring in a 1" bar.....forget it, you'll need a fatter bar. If everything runs when you fire it up your golden, what did you think of bars?
Thread Starter
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Road Master
Joined: Sep 2011
Posts: 764
Likes: 1
From: N. Texas
I couldn't wire internally due to the green plug+ the black plug+ all the wires from the controls. For those of you that did it, you must have removed the green & black plugs. Even staggering them it was just too much to fit into a 1" bar. As far as if I like the bars or not, not sure yet. They do feel a lot more comfortable but when I removed tranny cover I lost too much fluid(bikes lowered) & had to order more(all sold out locally).
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Stellar HDF Member
Joined: Nov 2004
Posts: 3,156
Likes: 41
From: So Cal
It can be done with 1" bars but it is tight and a PITA, but can be done. There are a few guys with Heritage Style Bars (1") that I ride with and they have done internal wiring.
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Elite HDF Member
Joined: Jul 2008
Posts: 3,524
Likes: 34
From: Maryland
Larger diameter bars still go down to 1" at both ends. So shouldn't that be a non-issue? Well, I guess it does give more room for play at corners. Sorry to hear ya couldn't get it run internal.