Spent 4 hours putting on the new bars on my 06 RK Classic. It was quite a chore getting all the wires pulled thru the bars to hide them. I learned a few tips to make the job easier. One of the things I did do to deviate from the instructions is I didn't disconnect the brake line from the lever. (I did put the cardboard spacer in between the lever and the housing like they tell you.) I also loosened the throttle cables to remove them from the handgrip but left them connected to the housing. You don't need to disconnect the battery cables just pull the Maxi fuse under the left side cover.

The first thing is not to waste the money buying the special tool to remove the pins from the connectors. You can do it just as easily with a small screwdriver. Make notes on exactly were each wire goes in each plug. There are 7 wires on the RK Classic's left bar and 8 wires on the right so make sure you know where they go.

Cut the factory plastic sheathing off about 3 inches from the switch housings. Replace this with a piece of 1/2 inch shrink tubing, it will make pulling the wires thru the bars alot simpler. 1/2 inch was the smallest tubing that would allow all the connectors to go thru. Tuck the shrink tubing under the factory sheathing about a 1/2 to 3/4's of an inch and use electrical tape to seal the joint. Heat the tubing with any heat source around. I used the salamander heater in the garage and it worked great. Make sure you put the supplied grommets for the holes at the top of the bars on before you pull the wires thru. The bottom grommets on the risers can be installed after you pull the wires, Just make sure you do it before you reinstall the plugs.

You need to put the cover for the fork lock on before you bolt the bars to the triple tree. Tork the bolts to 30-40 ft lbs and use red locktite on the bolts!! You don't want to have them come loose at an inconvient time. (Like when your on the highway.) The manual tells you how to adjust the throttle cables and you shouldn't have to adjust the cruise control cable unless you've disconnected the cables. Thats about it for now. Just take your time make a lot of notes on the wiring and go for it.

 

Here are a few pictures of the install:

Here is the initial tear down ready to get the new bars started.



Here is the view showing the ground wire on the bars and the shrink wrap on the right side wire bundle.



This is the left wire bundle pulled thru the bars and the bottom grommet inserted and the plugs reattached.

 

And a few more:

this is all the wires pulled and the connectors reattached. Note the fork lock cover is installed on the riser at this point.


These show the bars installed with a couple of different views.

 

this is the old look:


This is the new look:

 

I had similar bars on my 00 fat boy, mine were "Carlinis"
Good Job on your install and explanation....

 

good job look great.

 

Like the new look much better..great details on the install.

 

Nice write-up and pics. Looks great. If my EG didn't have a fairing, it would have been the very first mod I made to the bike--and if my aunt didn't have . . . (ya know the rest).

 

I love the look of the slammer bars. Gives the scoot a whole new look. Nice job!

Good walk through with the pics.

Now loose those old cables and brake line. BRAIDED!

 

Great job on the install. I am having the same bars installed on my custom this week, cant wait to see the bike when they are done. Have you put your windshield backon after the switch? How does that look?

Mike.