Need help changing handlebars

[cayestas]

I am knee deep in changing my handle bars from the stock 05 Bulldog bars to 06 Pitbull bars in order to give me a little more pullback (lean) when I ride.

Here's the problem - when removing the hand controls there is an electrical clip that plugs in to the controls that comes out of an oval shaped hole to accomodate the rectagular shape of the small wiring harness. At the bottom of the bars near the triple trees the whole where the wires feed into the bars is round and too small for the harness to easily come out.

Is thier a trick or does any one have any idea of how I can do this? The job is really done but I have to get the harness out of the existing bars and into the new set. If I can at least get it out, I can put them in sideways on the new ones and be done with it.

Thanks for the help.

 

[WB Cycles]

Normally (from what I can tell from talking with the service guys on a prior project), they feed the wires all the way through and then attach the plug after it is out of the bars. Its a little tricky to get the wires out from the plug and you have to be really careful about placing them in the correct slots when you set it up again.

 

[cayestas]

So are you saying that the wires will come out of the wiring harness...careful?

 

[WB Cycles]

The pins in the clip will come out using a small paper-clip / sewing needle with the right pressure on the release. I don't have any images, maybe Gas Man does in one of his builds?

 

[cayestas]

cool, thanks. I will try this and ket you know as I go. I am trying to avoid bringing it to the dealer in pieces...

 

[RRRUFF]

cayestas,
If I remember right when I change out my 05 chopper bars, I pulled the gas tank and unplugged the harnesses under there and was able to pull them out from the grip end of the bars. They should be the same on your 05 bulldog.

Also you will probably need some length on yours and you can re-arrange the wiring under the tank to get you a little more length. Just be sure to cinch everthing down under the tank so it won't rub the wires. You may want to go ahead and put some dielectric grease on all your connections while you are under there.

 

[MARV]

cayestas,
If I remember right when I change out my 05 chopper bars, I pulled the gas tank and unplugged the harnesses under there and was able to pull them out from the grip end of the bars. They should be the same on your 05 bulldog.

:2thumbs:

other end pulls right through.

 

[lee]

yep - I got an 05 Bulldog and had to do exactly that

 

[tucker]

u can do the old electricians trick ty a piece of string to one end tye the other to two cotton balls n suc right threw with your shop vac works every time when wen you pull the string threw the plastic end can be guided threw with needel nose plyers works for me hope i helped

 

[tucker]

i used l/a choppers bars on my k9 cut 14 inches off stock bars n then the same to the la choppers bars welded them back together re cromed n wala verry comferting bars utilized stock controlls they dont come cheep

 

[bdmridgeback]

This should get you through it:

http://www.bigdogbiker.com/forums/how/2598-swapping-ridgeback-chopper-bars.html

Did you try pulling the small plugs UP through the bars instead of pulling the large connector from the hand controls DOWN out the bottom?