Harley Davidson Forums
Leave the throttle sensor in the bars until after the bars are removed from the bike.
Leave the throttle sensor in the bars until after the bars are removed from the bike.
0 2014/07/22 03:01:16
Remove the castle bolts that secure the fairing to the fork legs. There are two on each side.
Remove the castle bolts that secure the fairing to the fork legs. There are two on each side.
0 2014/07/22 03:01:06
After the bottom two bottom castle bolts are removed slide the cover off the fork legs.
After the bottom two bottom castle bolts are removed slide the cover off the fork legs.
0 2014/07/22 03:00:54
Go to the front of the bike and lift the fairing straight up a couple of inches and lean it back.
Go to the front of the bike and lift the fairing straight up a couple of inches and lean it back.
0 2014/07/22 03:00:30
This is the TBW sensor wire. Follow it until you come to the plug. There is about 18" to 20" extending out of the bars.
This is the TBW sensor wire. Follow it until you come to the plug. There is about 18" to 20" extending out of the bars.
0 2014/07/22 03:00:20
Disconnect the TBW plug.
Disconnect the TBW plug.
0 2014/07/22 03:00:12
using a flat blade screwdriver gently pry the TBW sensor out of the bars. Once it is started push on the wire and gently pull the sensor out of the end of the bars.
using a flat blade screwdriver gently pry the TBW sensor out of the bars. Once it is started push on the wire and gently pull the sensor out of the end of the bars.
0 2014/07/22 03:00:00
This is the TBW sensor plug showing the wire colors.
This is the TBW sensor plug showing the wire colors.
0 2014/07/22 02:59:51
This is the TBW sensor plug showing the wire colors.
This is the TBW sensor plug showing the wire colors.
0 2014/07/22 02:59:42
This is the plug for heated grips. there are two wries in it.
This is the plug for heated grips. there are two wries in it.
0 2014/07/22 02:59:33
To remove the wires, pop the snap on the back of the plug open.
To remove the wires, pop the snap on the back of the plug open.
0 2014/07/22 02:59:24
Reassemble in reverse. Don't forget to use blue loctite thread locker on the handlebar bolts and the fairing castle bolts. Sorry there aren't any good pictures of the reassembly but i saw the light at the end of the tunnel and forgot to take pictures! lol
Reassemble in reverse. Don't forget to use blue loctite thread locker on the handlebar bolts and the fairing castle bolts. Sorry there aren't any good pictures of the reassembly but i saw the light at the end of the tunnel and forgot to take pictures! lol
1 2014/07/22 02:59:16
Look inside the plug and you can see the release tabs.
Look inside the plug and you can see the release tabs.
0 2014/07/22 02:59:06
While pressing on the pin release tabs gently pull the wires one at a time out of the plug.
While pressing on the pin release tabs gently pull the wires one at a time out of the plug.
0 2014/07/22 02:58:58
Plug diagrams with wire colors.
Plug diagrams with wire colors.
0 2014/07/22 02:58:50
Plug diagrams with wire colors.
Plug diagrams with wire colors.
0 2014/07/22 02:58:38
I used weed whacker line. It's stiff but flexible. I taped the wires in the middle of the weed whacker line so that I could push and pull on the line both ways if something got hung up in the bars.
I used weed whacker line. It's stiff but flexible. I taped the wires in the middle of the weed whacker line so that I could push and pull on the line both ways if something got hung up in the bars.
0 2014/07/22 02:58:28
All the throttle side wires are pulled through.
All the throttle side wires are pulled through.
0 2014/07/22 02:58:16
This is the left side switch wires. It's not shown here but i taped the wire and plug completely. These pulled through very easily.
This is the left side switch wires. It's not shown here but i taped the wire and plug completely. These pulled through very easily.
0 2014/07/22 02:58:02
Both Sides pulled through, time to put the plugs back on.
Both Sides pulled through, time to put the plugs back on.
0 2014/07/22 02:57:51
It really is as easy as orientating the pins correctly and pushing them into the hole until you hear a CLICK.
It really is as easy as orientating the pins correctly and pushing them into the hole until you hear a CLICK.
0 2014/07/22 02:57:40
I know the insert is still in place here, but with it removed you can look inside the plug and see the little latches that hold the pins in place. I used a small jewelers screwdriver to release the pin and at the same time push it out the back using a paper clip.
I know the insert is still in place here, but with it removed you can look inside the plug and see the little latches that hold the pins in place. I used a small jewelers screwdriver to release the pin and at the same time push it out the back using a paper clip.
0 2014/07/22 02:57:28
using a small flat blade screw driver pop the plastic insert out about an 1/8". By doing this you can push the wires forward from behind to take the tension off the pin latches.
using a small flat blade screw driver pop the plastic insert out about an 1/8". By doing this you can push the wires forward from behind to take the tension off the pin latches.
0 2014/07/22 02:57:16
Plastic insert popped out. when taking the plug apart remove this plastic insert completely by gently prying it out. it comes out easy.
Plastic insert popped out. when taking the plug apart remove this plastic insert completely by gently prying it out. it comes out easy.
0 2014/07/22 02:57:05
Once the wires are threaded through the bars you can put the TBW Plug back together.
Once the wires are threaded through the bars you can put the TBW Plug back together.
0 2014/07/22 02:56:53
This is the TBW sensor plug.
This is the TBW sensor plug.
0 2014/07/22 02:56:41
Now we have easy access to the handlebar clamps.
Now we have easy access to the handlebar clamps.
0 2014/07/22 02:56:31
Cut the two zip ties that hold the brake and clutch lines to the steering head.
Cut the two zip ties that hold the brake and clutch lines to the steering head.
0 2014/07/22 02:56:21
This will give you the extra play you need to move the lines around when you install the new bars.
This will give you the extra play you need to move the lines around when you install the new bars.
0 2014/07/22 02:56:07
If I knew then what I know now, I would have bought the switch wire extensions. There is enough play in the switch wiring but you have to remove the plug caddy, release the plugs (not pins), cut a bunch of zip ties, pull the switch wires to the back and and re-zip tie them. it was probably the worst part of this whole project.
If I knew then what I know now, I would have bought the switch wire extensions. There is enough play in the switch wiring but you have to remove the plug caddy, release the plugs (not pins), cut a bunch of zip ties, pull the switch wires to the back and and re-zip tie them. it was probably the worst part of this whole project.
0 2014/07/22 02:55:55
New Bars
New Bars
0 2014/07/22 02:55:44
New Bars
New Bars
0 2014/07/22 02:55:32
During the reassembly i found that when the clutch and brake master cylinders are pushed all the way up against the step in the bars it was impossible to rotate them forward to suit your particular liking.
During the reassembly i found that when the clutch and brake master cylinders are pushed all the way up against the step in the bars it was impossible to rotate them forward to suit your particular liking.
0 2014/07/22 02:55:21
Throttle Sensor plug wiring. **** (Be aware that on line there is a picture of this plug but the wire numbers are wrong. The colors are in the right spot but the pin numbers depicted on the plug are wrong)
Throttle Sensor plug wiring. **** (Be aware that on line there is a picture of this plug but the wire numbers are wrong. The colors are in the right spot but the pin numbers depicted on the plug are wrong)
0 2014/07/22 02:54:59
 
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