handlebar project
Thread Starter
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Outstanding HDF Member
Joined: Nov 2005
Posts: 2,408
Likes: 2
From: Houston (Area)
handlebar project
Ok Forum,
I mean business. Serious business. I ran during lunch and picked up a service manual. It looks pretty straight forward. I’m changing:
1) Bars
2) Grips
3) Master Cylinder
4) Levers
5) Switch Housing
6) Switches
7) Adding Stainless Steel Lines
Is there a particular order I should go in?
I mean business. Serious business. I ran during lunch and picked up a service manual. It looks pretty straight forward. I’m changing:
1) Bars
2) Grips
3) Master Cylinder
4) Levers
5) Switch Housing
6) Switches
7) Adding Stainless Steel Lines
Is there a particular order I should go in?
Seasoned HDF Member
Joined: Sep 2005
Posts: 5,072
Likes: 104
From: Prescott, AZ
RE: handlebar project
are you going with wires inside or outside the bars??
spacer on brake lever - follow inst in manual
be very careful NOT to pinch wires when putting back together - a member here on the forum did just that - ended up having the Stealer "redo" his work at $90 an hour.... ouch...
take your time..
spacer on brake lever - follow inst in manual
be very careful NOT to pinch wires when putting back together - a member here on the forum did just that - ended up having the Stealer "redo" his work at $90 an hour.... ouch...
take your time..
Outstanding HDF Member
Joined: Jul 2006
Posts: 2,407
Likes: 3
From: Stanwood, WA
RE: handlebar project
Hawg, I just did this except for the switches and master cylinder. Sounds like your going all chrome. Follow the manual, work on it when you don't only have an hour (all dayer) and NO BEER! 
The hardest (but it's not really hard) was my headlight shroud, housing, passing lights, chrome etc. Have some place to lay everything out nice and organized and cover the front fender up with a nice cushy blanket or something BEFORE you start! I had my passing light assy in my hand thinking "where do I put this now"? Manual even tells you that. Good luck, have fun! Dave
The hardest (but it's not really hard) was my headlight shroud, housing, passing lights, chrome etc. Have some place to lay everything out nice and organized and cover the front fender up with a nice cushy blanket or something BEFORE you start! I had my passing light assy in my hand thinking "where do I put this now"? Manual even tells you that. Good luck, have fun! Dave
Tourer
Joined: Jan 2006
Posts: 279
Likes: 0
RE: handlebar project
1) Cover all your painted surfaces with a nice fluffy towel or two. 2) Make sure you are in a good mood, feeling pissy and loosing your patience is the best way to horse this up. 3) If you get goofed up stop, have a beer, slap and tickle the wife.
When I did mine I pinched the RHS wires and when I applied the rear brake I got all my lights to light up. Took a little bit of time to work that out but, in the end, pretty simple stuff.
When I did mine I pinched the RHS wires and when I applied the rear brake I got all my lights to light up. Took a little bit of time to work that out but, in the end, pretty simple stuff.
Thread Starter
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Outstanding HDF Member
Joined: Nov 2005
Posts: 2,408
Likes: 2
From: Houston (Area)
RE: handlebar project
I guess I need to change my question.
Should I remover the Brake/Throttle/Idle cables first or should I remove the nacell (sp?) first to get to the bars or should I remove the master cylinder first?
Should I remover the Brake/Throttle/Idle cables first or should I remove the nacell (sp?) first to get to the bars or should I remove the master cylinder first?
Outstanding HDF Member
Joined: Jul 2006
Posts: 2,407
Likes: 3
From: Stanwood, WA
RE: handlebar project
Here's what I'd do. Nacelle first, which leads to the bars. Take the stuff off the bars and just let it all hang. Replace the bars, then go about replacing the grips, switch housings, switches and the master cylinder.
Thread Starter
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Outstanding HDF Member
Joined: Nov 2005
Posts: 2,408
Likes: 2
From: Houston (Area)
RE: handlebar project
Thanks Dave......I will start Monday. All my riding buddies that don't wrench want to come over. None of us have ever done anything like this.
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Outstanding HDF Member
Joined: Jul 2006
Posts: 2,407
Likes: 3
From: Stanwood, WA
RE: handlebar project
Give a hollar if you get stuck. I have a Classic also. You can also e-mail me if you want. Dave
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