How do you remove and replace Harley Davidson Road Glide handle bars?

Answer 1

Mine had wiring inside the bars as well. Basically I removed the controls from the bars, and removed the 2 bolts holding the handle bars on. I removed the RIGHT side gas tank after draining it. I intended on cutting the wires to the connectors, pulling the wires out of the old handle bars, and pulling them back through the new bars. Note: Mark the black wires very carefully, since there were 5 black wires in the two connectors and they are all unique wires. The colored wires were easy, just match them back up. Several tricks I found on line. Use a string and a bolt to fish a pull line down through the new bars then pull the wire bundle through. This worked great on both left and right wire bundles. I then bolted the new handle bars in place and remounted the controls. I then replaced the shrink tubing up the bundles that hid the actual wires as they came out of the handle bars down to where I cut the connector wires, behind the right side tank. Next I stripped and tinned all the wires I cut (twist and get a little solder to stick on the wires) and stuck little pieces of shrink tubing up or down the wire so after I resoldered the wire I could shrink the insulation back over the splice. I picked up the shrink tubing and some extra wire a Home Depot. I had a soldering iron, and heat gun so away I went connecting the dots again. Litte tedious but hey. It saved me somewhere between $500 -$700 bucks which is what the harley shop quoted before I started. I tested each function, then reinstalled the gas tank and tightened up all the stuff. Below is the pin out in case you do loose a wire marker, like I did. Good Luck. {| |- | 1993 HARLEY DAVIDSON Softtail CustomInterconnect Harness for Handle Bars Black

Rt. Turn Lamp

Run Light Black

L. Turn Lamp

Run Light Black

L. Turn Lamp

Signal Light Yellow

HeadLight White

Headlight Blue

Left Head Light

High / Low Yellow

Left Head Light

High / Low Grey

Run / Kill Switch Black

Rt. Turn Lamp

Signal Light Violet

Left Turn Switch Red

Rt. Front

Brake light switch Brown

Rt. Turn Switch Orange

Horn White

Left Head Light

High / Low Orange

Rt. Front

Brake light switch White

Run / Kill Switch Green

Left Turn Switch Black

Horn Green

Rt. Turn Switch Black

Starter Switch Left Right |}