handlebar removal

[sloan2]

i want to change out my bar to a set thats powder coated. wanted to know how hard of a job it is. mainly the wires in the bars. how do u remove them without fucking them up? do i have to remove the pins from the connectors or will they fit through the hole? dealer said it would cost about 350 and would take about 4 hrs. any help would b great and thanks in advance. mike

 

[Raywood]

I wouldn't pay the dealer that much for such a simple job. Yes the pins with fit though the bars without taking them apart.
Take you about an hour to pull it all apart and some time to put it back together but not to hard a job. Don't have them powdercoat the bar ends.

Will look good when you get it done. I think I will do the same this winter.

:flag: :flag:

 

[mobsta]

easy job but remember bd handle bar size not the same as the rest of the world

 

[sloan2]

There bd bars same year and model just powder coated black. So when I remove the controls and unplug the wires I can just let the controls hang to the side and I guess the same with speedo? Any tricks with wires I should know before I start?

 

[Raywood]

There bd bars same year and model just powder coated black. So when I remove the controls and unplug the wires I can just let the controls hang to the side and I guess the same with speedo? Any tricks with wires I should know before I start?

When you take apart the throttle side you need to be carefull with the cable ferrel's. The are easy to loose, same as the brake magnet so be careful on that side. But the wires pull right through the bars easily. May be a pain getting the wires back in the bars after you have them done so use some fishing line and maybe a vacuum to help chase them up the bars. While you have the bars off you may as well replace the rubber bushings with some good polyurethane ones. You can get them from any mail order place or order them from Chubby's.
Get some die-electric grease and fill all the connectors before replacing.

You doing black bars? I may do that as my struts are black.

 

[sloan2]

Yeah I'm doing them black. Going to do my struts, headlight and mayb wheel but don't known how those wheel would black. Trying to go for that limited edition look.

 

[mobsta]

yeah what he said or string and compressed air works also.

 

[sloan2]

Well got home opened the box my bars just got delivered in and it looks like the box was dragged behind the truck. Poweder coat was all fucked up so luckily the powder coater was still there when I called and I was able to drop them off tonight. Said they'll be done tomorrow afternoon. So I guess I'll wait until I get them back so I can't still ride tomorrow. I'll keep u posted when I start sure I'll need some help and thanks for your responses

 

[MARV]

pull the wires from the bottom up.

the connectors at the controls are too big to fit through.

 

[lee]

yeah thats what I was going to say - I wish i knew that BEFORE i did mine, would have saved a lot of time

did you buy new bars or just get your old ones powder coated?

 

[Nomad2day]

Mike,
Did someone local do the powder coating?
Neil

 

[sloan2]

yeah thats what I was going to say - I wish i knew that BEFORE i did mine, would have saved a lot of time

did you buy new bars or just get your old ones powder coated?

I bought a pair that was already powdercoated

 

[sloan2]

Mike,
Did someone local do the powder coating?
Neil

No I they were already powder coated. I'm having the guy at hardshell recoat them today. Should have them by this afternoon.

 

[Nomad2day]

If you do them while we are off for the shutdown give me a call and I will come by if I am not into anything. Me and Richard the ex Harley service manger are going to Nashville Wednesday on the bikes to do a little bar hopping and have some fun if you are up to it.....
I am getting ready to go out on the bike now. I have been going for a morning ride everyday seeing how we are off and jumping in the Z06 later in the day and doing a little running around. I have been trying to lower the beer availability in this town while we are off.
Neil

 

[sloan2]

pull the wires from the bottom up.

the connectors at the controls are too big to fit through.

does this mean I have to take the tank off? Are there connectors under the tank?

 

[Nomad2day]

Yes, there are connectors under the tank on the backbone harness that go to everything on the front of the bike. They "the harness" are wrapped up in a Velcro blanket for a lack of a better description.
Neil

 

[sloan2]

I might take you up on that offer later i'm going to try and do it tonight if I get the bars back. I think I'm helping someone move tomorrow. What time you going to Nashville. Pm me your number

 

[sloan2]

Neil, where are you going to ride today?

 

[Gas Man]

here are some threads to help

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

More detail on the hand control side of life
http://www.bigdogbiker.com/forums/how/341-how-swap-out-pegs-grips.html

 

[sloan2]

i got the chrome bars off and actually got the wires in the powdercoated ones pretty easy only took about 5 minutes. put the bars back on,put the tack back on went to put the controls back on and:angry: the powdercoat was way to thick.:bang: controls weren't even close to going on. they were powdercoated three times now there way to big. I'll have to take them back and have them strip them down to bare metal. and have them not put it on so thick