Print

Please login or register.
1 Hour 1 Day 1 Week 1 Month Forever
Login with username, password and session length

[2006ULTRA]

I got the bike all tore apart tonight and didn't realize from all the research I've done that there is three wiring harnesses that come out of the bars.  It seems like it going to be pretty tight getting everything back through the bars??  Plus I'm installing heat demons.

First question is how hard is it to get the TBW housing out of the stock bars?  Is it fragile etc?  I really didn't mess with it much but it didn't slide right out.

Is there an online video that shows how to take the harness plugs apart to separate the wires so I can pill them back through the bars?  I did this 5 years ago on my 06 Ultra but don't really remember the process.  Plus I didn't have near as many wiring harnesses to deal with.

Any tips would be appreciated.  I am finishing up the job hopefully tomorrow.

Thanks Brett

[Twolanerider]

I got the bike all tore apart tonight and didn't realize from all the research I've done that there is three wiring harnesses that come out of the bars.  It seems like it going to be pretty tight getting everything back through the bars??  Plus I'm installing heat demons.

First question is how hard is it to get the TBW housing out of the stock bars?  Is it fragile etc?  I really didn't mess with it much but it didn't slide right out.

Is there an online video that shows how to take the harness plugs apart to separate the wires so I can pill them back through the bars?  I did this 5 years ago on my 06 Ultra but don't really remember the process.  Plus I didn't have near as many wiring harnesses to deal with.

Any tips would be appreciated.  I am finishing up the job hopefully tomorrow.

Thanks Brett

Getting it all in and out of the bars is a bit of a chore.  But it's (obviously) do-able.  The sensor can be delicate.  Several anecdotes here of them not surving the R&R.  All you can do is be careful.  The harness connectors can also be a nuisance.  One of those "you have to hold your mouth right" things for the releases to sometimes release. 

My tool of preference to release them has become a large sewing needle.  Go to Wal-Mart and get an assortment pack so you can find the right size for the chore.  I'm sure there must be a gauge or other size measure for sewing needles that could be shared.  But I'm a fat-phuk-male and I don't know crap about them.

[2006ULTRA]

I hear you on holding your mouth just right deal. LOL

After having a couple stubborn bolts almost strip and worrying about scratching something I kept asking myself if I really needed these bars and heated grips.  I had another beer and starred at the whole deal.  Then I kept going, then another beer and finally everything was apart. 

So now I'm committed and hopefully everything comes together tomorrow.

[Twolanerider]

I hear you on holding your mouth just right deal. LOL

After having a couple stubborn bolts almost strip and worrying about scratching something I kept asking myself if I really needed these bars and heated grips.  I had another beer and starred at the whole deal.  Then I kept going, then another beer and finally everything was apart. 

So now I'm committed and hopefully everything comes together tomorrow.

Good luck man.  Since it never hurts to restate the obvious I will one on thing.  Make yourself a good map of the harness plugs before disassembly.  I always do.  I even snap pictures sometimes.  But the first time I took apart one of the bikes like yours I didn't pay enough attention. 

Said several bad words taking those AMP style connectors apart.  Once finally got the "feel" it was better.  But I didn't pay enough attention during all the mental ruckus and subsequent reassembly.  Got one pair of the six wires to the throttle sensor together incorrectly.  Was further screwed by the fact that the bike actually ran normally.  All worked fine but the check engine light was on and the cruise didn't work.  Found the problem later obviously.  But I wasn't attentive enough to begin with at least partly because I got so pissed off at the wire connectors.

So...  the beer breaks are a good idea.  Have fun.  Enjoy it when it's all done.  That's a great set of bars for a bagger.  They're on my Electra Glide and feel great. 

[faceracer]

Getting it all in and out of the bars is a bit of a chore.  But it's (obviously) do-able.  The sensor can be delicate.  Several anecdotes here of them not surving the R&R.  All you can do is be careful.  The harness connectors can also be a nuisance.  One of those "you have to hold your mouth right" things for the releases to sometimes release. 

My tool of preference to release them has become a large sewing needle.  Go to Wal-Mart and get an assortment pack so you can find the right size for the chore.  I'm sure there must be a gauge or other size measure for sewing needles that could be shared.  But I'm a fat-phuk-male and I don't know crap about them.

I think that's why most of of purchased a kit before hand. Twist Grip Sensor Kit (TBW)   : Part # 32310-08

[Twolanerider]

I think that's why most of of purchased a kit before hand. Twist Grip Sensor Kit (TBW)   : Part # 32310-08

So far the two I've had apart survived the R&R without needing replacement.  So with luck and the Travel Gods on your side it can happen.  But it's not a sure thing.

[SG Racer]

Like some others said, it can be done. Just be careful and it should come out. I have done a few and have never replaced the TBW sensor.
 Things will go better once you get the wires pulled in the new bars. It is always a scary experience if you have never done it.
 Good luck and take your time.
 Ray

[Wayne G]

If you go to the Chubby 575  website they explain the process of harness connector disassembly.  They suggest and I used a large paper clip, I filed a slight angle on the end like a blunt screwdriver so it will slid down into the connector and not hang up on the small plastic release tabs. The best thing you can do is write down the harness type, wire color and positions in the connectors before removal (position numbers are molded in connectors)  double and triple check before you remove wires and when reassembling.

[Cvostu]

I really like the 575s.  But I'm leaving the stock bars on for now.    I guess I'm gonna learn to like em after reading all this.   

[Boatman]

I really like the 575s.  But I'm leaving the stock bars on for now.    I guess I'm gonna learn to like em after reading all this.  

Stuart-

As many miles as you ride, put on the bars that are comfortable to you.  The stock bars about worthless for most people.

Regarding the bars and the wiring.   If you go into the change  thinking you can do it in a couple hours, you can't.  Leave several days for the job and when you get frustrated just stop and come back to it later.


The wiring plugs aren't that hard once you get the hang of it.

[2006ULTRA]

I have all the wires out of the bars but I can get the TBW small 2 pin black plug apart??  I don't think it will go through the bars assembled.

Is there a trick to get this one apart?

[mandm1]

I have all the wires out of the bars but I can get the TBW small 2 pin black plug apart??  I don't think it will go through the bars assembled.

Is there a trick to get this one apart?

That small 2-pin connector is for the heated handgrip portion of the TBW assembly. Disassembly is covered in the service manual; basically you pop out the green wedge inside the connector, then spread open two plastic "legs" while gently pulling the wires out from the back. I'm changing my bars to 12" Yaffe Monkey Bagger bars right now, so I'm going through the same process as you. I created a PDF of the wiring on my 2011 SESG. Please see the attached file. Hopefully this will help keep the connections in the proper order ...

Mike

[Midnight Rider]

That small 2-pin connector is for the heated handgrip portion of the TBW assembly. Disassembly is covered in the service manual; basically you pop out the green wedge inside the connector, then spread open two plastic "legs" while gently pulling the wires out from the back. I'm changing my bars to 12" Yaffe Monkey Bagger bars right now, so I'm going through the same process as you. I created a PDF of the wiring on my 2011 SESG. Please see the attached file. Hopefully this will help keep the connections in the proper order ...

Mike

Excellent PDF diagram...

[2006ULTRA]

Can I hook my heat demons up to this port?

[Twolanerider]

Excellent PDF diagram...

Agreed.  Saved a copy.  Never know when something that good might come in handy.

[mjb765]

Agreed.  Saved a copy.  Never know when something that good might come in handy.

X2   

[2006ULTRA]

Got everything back together, have a few problems.

I installed Harley LED lights and one of the AUX lights is defective.  Tested the wires and it's the light.  No big deal.

I also installed heat demons and since I have the hidden antenna I didn't want to use the cig lighter to power it since it had the ant hooked up there.

I hooked the heat demons up to the lead for the harley heated grip plug and they won't power up??  I know they work because I tested them twice before installed the bars.  I need to figure that out tomorrow.

I dropped a fairing bolt down in to the triple tree and we looked for it for hours lol.  It landed in a towel I had on the front fender,

Other than that everything went well.

[Twolanerider]

Got everything back together, have a few problems.

I installed Harley LED lights and one of the AUX lights is defective.  Tested the wires and it's the light.  No big deal.

I also installed heat demons and since I have the hidden antenna I didn't want to use the cig lighter to power it since it had the ant hooked up there.

I hooked the heat demons up to the lead for the harley heated grip plug and they won't power up??  I know they work because I tested them twice before installed the bars.  I need to figure that out tomorrow.

I dropped a fairing bolt down in to the triple tree and we looked for it for hours lol.  It landed in a towel I had on the front fender,

Other than that everything went well.

One thing to keep in the back of your mind on the Heat Demons.  Have installed several sets and only one gave any kind of problem.  But it was a slightly unexpected problem.

That set would work while testing them.  With everything pulled through the bars and hooked up but with the elements hanging out the ends all was fine.  So shoved it all together.  Then, oops, they didn't work anymore. 

Back apart with the elements hanging out the ends all was good.  Slide the elements back inside the bars; no go.  The left element was shorting against the bars when it was installed.  The Heat Demons folks sent a new left element in a next day padded envelope and all was good.  But it took ten minutes of in and out with the element for me to know for sure what was going on.

[2006ULTRA]

I didn't test the factory lead that comes out of the TBW harness for factory heated grips so maybe thats the problem??

What sucks is now I have to take the everything apart again to check the leads.  I guess I would have done it earlier but I didn't have the battery hooked up because I wanted to get all the lights hooked up and the fairing back on.

It's always something

[Midnight Rider]

I didn't test the factory lead that comes out of the TBW harness for factory heated grips so maybe thats the problem??

What sucks is now I have to take the everything apart again to check the leads.  I guess I would have done it earlier but I didn't have the battery hooked up because I wanted to get all the lights hooked up and the fairing back on.

It's always something

[smiley1049]

make sure you have the polarity of the leds correct or they wont work

[2006ULTRA]

I pulled the fairing back off and ran the Heat Demon wires to the Cig lighter.  They work fine now.  Not sure why the factory heated grip plug didn't work but oh well.

Basically everything is done now. 

I have two minor issues;  I ordered the 1" heat demon kit instead of the 1 1/4" so the housing doesn't fit the WO 575's.  My fault.  Heat Demons is sending me out a new housing to swap it out.  Pretty cool guy's over there.

I also installed the LED headlight and LED AUX Lamp kit.  One of my Aux lamps was defective so I had to send it back, still waiting for a replacement.

Other than that everything went pretty well.

I think the next time I have to take the radio out I will order a new rubber gasket that goes around the radio by the face plate.  It got a little beat up taking the radio in and out twice so I could fix the Heat Demons.  The second time I put the radio in I used a little WD-40 around the gasket so it would slide in better without tearing.

[2006ULTRA]

Couple pics;  it's going to be 55 degrees today so I put one of the old AUX lights back in so I can go ride.

[Twolanerider]

I also installed the LED headlight and LED AUX Lamp kit.  One of my Aux lamps was defective so I had to send it back, still waiting for a replacement.

Just in case it still doesn't work when the new light arrives I'll mention something you've probably already checked.  At the risk of being redundant....

If it still doesn't work check the socket that the light plugs in to.  Put a set of those on a local's bike a few months ago after he'd tried and scratched his head.  The OE socket was wired backward.  Standard bulb doesn't care about polarity.  The LEDs do.

[2006ULTRA]

Thanks for the tip!  I'll check that just to be sure.