Replacing hand control swithes on 03 and older

Mr. Wright

Knows some things
I had to replace my right signal switch, and decided to do a how to, for those who need to know. These are Harley style switches and rather easy to do. Looking at the picture, the two cables on the bottom, are your throttle control cables. Take a marker and mark front and rear. Then back off the lock nuts, and turn the adjusters all the way in.


Now take the two bolts out of the brake master cylinder bracket. And carefully lay it over the handle bars.


One of the bolts is found under where the handle was, and the other is next to the signal light switch.


Take the cover off the top, while supporting the bottom of the cover. Remove the front throttle cable, being careful not to loose the little brass keeper on the end of the cable. them remove the rear. The cables will now just pull out of the cover.


Inside is straight forward, Remove the screw that is holding the switch your changing out.


Your new switch will come with more than you need.


Cut the little piece of heat shrink in half, so you have two pieces. Slide them over the wires, twist the wires together, and solder the joint. Then slide you heat shrink up and seal.


Now is a good time to clean the inside of you throttle grip. DO NOT USE GRAPHITE TO LUBE. I like to shoot a couple shots of penetrating lube in there is all. Now reassemble in reverse order. Use the outer bracket to find your spacing.


Remember when you putting the brake handle assembly together, the handle will have to be pressed to clear the brake switch, and make sure all your wires are pushed up out of the way, so they don't get pinched.
Note in the last picture, the small piece of green tape. I've found that it helps to keep everything from twisting.
This job took me 20 minutes to do.
 

Mr. Wright

Knows some things
Opps, don't forget to readjust your throttle cables. The outer cable on the carb, has a spring in it. The forward twist of the grip, or deceleration movement, will press that spring. Adjust so you have to move the throttle forward the make the spring depress. I hope that makes since.
 

Jeff lohman

Member
Thank wright that helps me a lot on the way they come apart. Is there any year of Harley switch that I need to get to replace the one on my 03 Dog
 

Jeff lohman

Member
Took mine apart and found that the switch housing where the return spring goes was broken found a used plastic start switch housing from a friend that runs a motorcycle repair shop he gave it to me and it back together and on to the drive belt and wheel bearings thanks Mr wright for the great how to
 
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