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[REGGAB]

Terry used to do these step-by-step installations with pictures.  I haven't seen one on here for Heat Demons yet, so figured I'd put one together during an installation and post it, so everyone knows...........it IS NOT that difficult or involved.  In fact, it is quite alot of fun.
Not long ago, Scott (sadunbar) listed a set of Heat Demons for sale on this site.  I guess I lucked up and got to it first.  As one individual put it, it was "$90.00 pure profit" for him, since he got a double shipment of Heat Demons, but for me, it was a set of Heat Demons as much as $50 less than some places sell them........and a really fun mod for the FLHR.  I took the day off today, and decided to enjoy some time in the garage installing the Heat Demons.  So here we go.  Here's a picture of everything that comes in the Heat Demons kit.

[REGGAB]

Here's a "before" picture of the FLHR.

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On the J&S Jack, battery disconnected, windshield off, and probably over protected, but I recently learned this lesson the hard way.   

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Right grip removed.  Don't forget to stick something like a popsicle stick between the brake lever and the reservoir mount, so you don't break the brake light switch upon reinstall.

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Left grip removed.  This took some "doin'."  It was on there.  Ended up heating it with a heat gun and twisting it off.  Finally broke loose.  Note the green mark on the bar.  That is so I know how far to shove the grip back on when it came time to reinstall.

[REGGAB]

You'll need to step drill a 5/16" hole in the bar on the left side for the controller and power wiring.  I started at 3/32" and worked my way up to 5/16".  Then I deburred using a dremel with a stone tool.  Hole needs to be in the outer edge of the wire crease as shown.

[REGGAB]

Kit comes with a plastic snake to help thread the right side grip warmer wiring to the left side.  You gotta hold your mouth right to get this thing through the bends in the bars, but it isn't too bad...........just crank the tunes, grab a beer, and have fun with it.  Be sure the end of the snake that has the hole in it comes out the right side of the bars.

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Put the yellow and white wires from the right side grip through the hole in the end of the snake and carefully pull the wires through the bars.

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Figured this would be a great time to do a clutch, throttle, and idle cable lube, so I pulled out the INOX and made it happen.  For cable clutches, I put the collar back together, stick a piece of PVC through the hole, hold the clutch disengaged, and squirt INOX into the cable housing.

[REGGAB]

After you've lubed your cables, insert the right grip warmer into the bar and reassemble the right grip.

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Next, insert the supplied rubber grommet into the 5/16" hole you made in the left side of the bar earlier.

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Then thread the four wires of the controller and power cable through the grommet and out the left end of the bar.  Helps to do this one wire at a time.

[REGGAB]

This part was simple.  Trim the protruding wires to 4 inches or so.  Using the supplied telephone wire splices, match up the colored wires.  Five splices total.  Green and red are two wire splices.  Yellow, white and black are three wire splices.  Shove the ends of the wires into the telephone splices, and squeeze them with a pliers until dielectric grease comes out.  Tug gently to ensure security.  Wipe off the grease.  Too easy.

[REGGAB]

Gather the wire and splices inside the left grip warmer and shove the grip warmer inside the bar, pulling the power cable as you shove the grip warmer into the bar.  Now is a good time to check your work.  Attach the power cable to a 12VDC power supply (battery) and turn on the switch on the controller.  Be sure it steps through 4 levels, the lights indicate accordingly, and the grips get warm.  Press & hold the switch and be sure it will dim for night riding.  Press & hold it again to make sure it will return to bright setting.  Turn off the controller.  Disconnect power supply.

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Mix the supplied epoxy and apply to the inside of the grip.  Slide the grip onto the bar and reassemble the switch housing.

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Assemble the clutch handle using the Heat Demons controller as the new collar half.

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You have choices here as to how you wish to power your Heat Demons.  On an 02 FLHR there is a switched hot and common in the same harness as the headlight connector, so that is what I used.  I trimmed the power cable, clipped off the female spade connectors from the switched hot and common, readied heat shrink and tinned the bare ends of the stripped wires.

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Next I stagger solder spliced the hot and common wires to their Heat Demons mates.

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Covered each polarity with two layers of heat shrink and joined with a single layer of heat shrink.  I used aviation lacing tape to secure the union to a harness inside the headlight nacelle.  Then buttoned everything up.

[REGGAB]

MOC OK.

[Fired00d]

Henry,
Great job, and excellent step by step write up. I'm still skeered of wrenching though.

 
Ride Safe,
Fired00d
 

[HDBaggerDave]

Thanks, well done!!  I'm doing one for someone this weekend...your timing is perfect.

[SBB]

Henry

Now this is a great thread.
You made it happen and documented it with photos.
Great job and you didn't even need a surrogate to help.

Can I make a suggestion?
The 02 is a great bike and I would appreciate seeing some pictures of it.
With the changes you have made I know you have to enjoy that ride.
Your 02 R/K to you is like my 03 Classic to me, not a CVO but a damn fine bike that I'm proud to ride.
Take some pictures and show us!

Again, a great how to thread backed up with great pictures!
This site needs more of this.
Thanks Henry!

SBB

[REGGAB]

Henry,
Great job, and excellent step by step write up. I'm still skeered of wrenching though.

 
Ride Safe,
Fired00d
 

Thanks, Gary.  I had alot of fun doing this.  Maybe is was because I was so stressed out from this week, but I really enjoyed this mod.  I've had the grip warmers for awhile, but either haven't had the bike or the time to get them installed.  It really is a simple task.  I can see it being a little more involved on an FLHT with internal wiring, but even then, the snake would make quick work of the task.........and I know plenty of switched hot circuits under the fairing cap.  You can do this.  Honestly.

Thanks, well done!!  I'm doing one for someone this weekend...your timing is perfect.

You're welcome, and thank you!  You'll enjoy it.  I need to get another set of Heat Demons for my SEUC and install them when I install the WO575s.  Really looking forward to that mod.

Henry

Now this is a great thread.
You made it happen and documented it with photos.
Great job and you didn't even need a surrogate to help.

Can I make a suggestion?
The 02 is a great bike and I would appreciate seeing some pictures of it.
With the changes you have made I know you have to enjoy that ride.
Your 02 R/K to you is like my 03 Classic to me, not a CVO but a damn fine bike that I'm proud to ride.
Take some pictures and show us!

Again, a great how to thread backed up with great pictures!
This site needs more of this.
Thanks Henry!

SBB

Thanks Chip!  The 02 FLHR is really growing on me.  I've become quite fond of it in the short time I've had it.  It looks so much better now that those eagle stickers are gone.  If it is sunny tomorrow, I'll take a break from the books, roll it out in the driveway, take a bunch of pictures and post them.  It has been pretty well maintained for a 8 year old (Aug 01 build date).  Needs a good working over with Glare Micro and Spider, followed by two coats of Glare Pro Polish.  13,250 and change on the clock.  Runs out great for a TC88.  Other than a set of Wood's TW6G cams, S&S gears, a SE cam plate, new style oil pump, OEM lifters, SE adjustable pushrods, a set of Vance & Hines Duals, and maybe a Baker OD6 and 3.37 primary gearing, it won't see too many performance mods.  As she sits, she puts out 70 HP and 81 lb/ft TQ.
I intend to do the engine and transmission work myself, just not sure when, but I'll chronicle those mods here in pictures as well.

[Boatman]

Nice pictorial "how to"  Henry.  Have done a Fatboy and 2 Electraglides.  The Eglides are a little more difficult but the install is the same.  They also have them for Throttle by wire too.  Those you have to buy direct from them at this time.

[sadunbar]

Great job, Henry!   

[naitram]

nicely written install guide

[REGGAB]

Nice pictorial "how to"  Henry.  Have done a Fatboy and 2 Electraglides.  The Eglides are a little more difficult but the install is the same.  They also have them for Throttle by wire too.  Those you have to buy direct from them at this time.

Thanks, Bob.  I agree FLHT is going to be a bit more involved, therefore more time consuming, especially with internal handlebar wiring, but I'm not so sure it is anymore difficult. Great reason to drink another beer or seven and have fun with it.  Projects like this need to be done when there is nothing else pending on the horizon.  If one rushes it, it could go bad quick, fast, and in a hurry.
I haven't seen a TBW kit.  Know a few guys with TBW who want heated grips..................one has had TBW challenges. 

Great job, Henry!   

Thanks, Scott, and thank you for the great deal on the grip warmers.  BTW, how are your $29 grip warmers doing?   

nicely written install guide

Thanks, Neal.  Pretty simple on an FLHR.  It was fun.

[spydglide]

Very nice job of step by step pics of the install Henry.  You make it look so easy.  har!  spyder

[REGGAB]

Very nice job of step by step pics of the install Henry.  You make it look so easy.  har!  spyder

It was easy, Spydy.  Fun too.  Didn't you just install as set on your Huckleberry?

[spydglide]

It was easy, Spydy.  Fun too.  Didn't you just install as set on your Huckleberry?

Yeah, but wasn't easy or fun.  Finally had to remove all wiring from handlebars to get the wires in there.  But, gotta say that I love them now that they're done.  har!  spyder

[REGGAB]

Yeah, but wasn't easy or fun.  Finally had to remove all wiring from handlebars to get the wires in there.  But, gotta say that I love them now that they're done.  har!  spyder

Hmmmmm.   I know this is too little too late, but I'm bettin' that if you'd sprayed the snake with a 10:1 solution of water to dish soap, it would have slid right past all that internal wiring.  Windex might have worked too.  There's potential for the snake to be aggravating if allowed to be that way.

Just the same tho', you're done, they work, your hands are warm, and that makes for a happy Spyder!   

[spydglide]

Hmmmmm.   I know this is too little too late, but I'm bettin' that if you'd sprayed the snake with a 10:1 solution of water to dish soap, it would have slid right past all that internal wiring.  Windex might have worked too.  There's potential for the snake to be aggravating if allowed to be that way.

Just the same tho', you're done, they work, your hands are warm, and that makes for a happy Spyder!   

You bet.......my ole joints really don't like the cold anymore and that heat coming up thru the gloves is velly nice! Now that I see how nice, I'll be looking to do the grips on Ole Granny also.    har!  spyder

[REGGAB]

You bet.......my ole joints really don't like the cold anymore and that heat coming up thru the gloves is velly nice! Now that I see how nice, I'll be looking to do the grips on Ole Granny also.    har!  spyder

Well there ya go!  You can use the soap trick then.   

Grip warmers on the Green Bike still work........somewhat.  Need to get a free weekend during a term break and go ahead an knock out the WO575 installation and switch to Heat Demons.  That will be a fun task for sure.