Removing handlebars

cueball

Member
Is there an easier way of removing the switch harnesses from the handlebars? I want to remove my bars to get powdercoated but it appears the harness comes out of the bars and then runs thru the back bone to the ecu. Either I have to take the connectors off the ecu and pull the harnesses or cut the wires near the neck and wire back together after the bars are powdered any suggestions I cant imagine its this complicated.
 

spadesluck

Active Member
I beleive cutting is the only way to get the wires out of the bar. One end has the connectors and the other end has the switch boards, which neither will fit to take out. You have be able to pull the pins out from the connectors without cutting.
 

cueball

Member
Ok I will go look again I am going to remove the tank today anyway. Thanks for the info I just glanced earlier and didnt see any connectors but I didnt look real hard. I wouldnt think they would have ran solid wires from one end to the other but I wasnt sure.
 

Bowhunter

Well-Known Member
Richard,
I changed out the bars on my K9 to Ridgeback bars so I have pulled the wires to switch the handlebars on my bike and Postman's bike to do a swap. NO CUTTING is required, remove your tank and on the backbone will be a connectors where you can disconnect your wires from your handlebars. A quick labeling of the connectors will make hooking the plugs back up a snap later. Remove the grips with the controls off each side and disconnect the wires from the controls. After you have removed both controls, you can remove your handlebars and carefully pull the wires up toward the handgrip cutout until they are removed from the bars.
To reassemble, run a cord into the handgrip cutout down to the cutout at the base of the handlebar and then tape the undertank plug to the cord and put it carefully thru the bars. A thin pair of needlenose pliers allow you to pull the connector thru the slot. Fill the connector with dielectric grease and reconnect after you mount the handlebars. While you have the tank off, fill all the connectors with dielectric grease to prevent water from entering at any time in the future. All you really need is patience and care and you can do the job easily.
 

cueball

Member
Awesome once the tank was removed I located the connectors everything from there was pretty self explanatory. Great idea to use the dielectric grease and I have had a front turnsignal that had been acting up occasionaly and today I found a pinched wire under the tankso I fixed that also.
 
Top