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Author Topic: Broken handlebars  (Read 1467 times)

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Proraver

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Broken handlebars
« on: November 11, 2020, 09:48:30 AM »

I went to install a new radio and discovered my bars were snapped in half. So I was looking to install the WO578 10" bagger bars. Does anyone know if I am going to need longer hoses and wire extensions? I searched all over but I can only find info on newer bikes. Any help would.be greatly appreciated, I've never done anything like this before.
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efrbc1

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Re: Broken handlebars
« Reply #1 on: November 11, 2020, 10:19:09 AM »

Can't answer your question about longer cables/wires (but I'm guessing you will need to extend what is stock) but make sure you use a one piece (full width) top clamp when you change them out.  Probably would have kept the stock bars from breaking.
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ultra13

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Re: Broken handlebars
« Reply #2 on: November 11, 2020, 10:38:07 AM »

Def get the 1 piece upper clamp! You can go to 10" bar with the stock wiring. After 2013 you can go 12 maybe 14's with stock wiring. Also buy new bushings with your new bars.
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Ironhorse

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Re: Broken handlebars
« Reply #3 on: November 11, 2020, 10:55:10 AM »

I’ve seen that happen when folks use the handlebars as strap down points on a trailer. And yes, get a one piece top clamp.
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Proraver

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Re: Broken handlebars
« Reply #4 on: November 11, 2020, 11:18:36 AM »

Thanks everybody. I've never trailered it but the guy I bought it from had the dealer haul it back and forth all the time for service work. I did buy the top clamp and will definitely change the bushings while I have it apart.
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JCZ

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Re: Broken handlebars
« Reply #5 on: November 11, 2020, 11:26:13 AM »

I believe Harley did away with that two piece top clamp years ago.  My last three CVOs had the one piece top clamp.

But I can tell you what it was like riding my 86 Heritage with bars to the stars down the highway and all of a sudden one side was just dangling in my hand......at freeway speed.  Real pucker factor right there!
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porthole

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Re: Broken handlebars
« Reply #6 on: November 11, 2020, 12:51:42 PM »

My wires were OK but I had to replace the brake lines.
And as suggested above, one piece upper clamp.

I'm still surprised this was never a NHTSA recall item.
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Twolanerider

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Re: Broken handlebars
« Reply #7 on: November 11, 2020, 12:59:05 PM »

My wires were OK but I had to replace the brake lines.
And as suggested above, one piece upper clamp.

I'm still surprised this was never a NHTSA recall item.


I'm surprised it took visual inspection to find that.  Normally if bars break it's one of those thing you discover with a high degree of enthusiasm.
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porthole

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Re: Broken handlebars
« Reply #8 on: November 11, 2020, 01:38:29 PM »


I'm surprised it took visual inspection to find that.  Normally if bars break it's one of those thing you discover with a high degree of enthusiasm.

And we know you have had your share of "high degree of enthusiasm's"  :'(
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spydglide

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Re: Broken handlebars
« Reply #9 on: November 11, 2020, 02:03:44 PM »

And might I suggest that while you're in there re-wiring take the opportunity to wire in some heated grips.  They're GREAT!  har!  spyder  :huepfenjump3:
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porthole

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Re: Broken handlebars
« Reply #10 on: November 11, 2020, 05:02:16 PM »

And might I suggest that while you're in there re-wiring take the opportunity to wire in some heated grips.  They're GREAT!  har!  spyder  :huepfenjump3:

Yeah - what he said.

I use my grips almost year round.
Long rides the heat feels good.
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ultra13

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Re: Broken handlebars
« Reply #11 on: November 11, 2020, 09:55:34 PM »

Love my 10" Wild ones.
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Twolanerider

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Re: Broken handlebars
« Reply #12 on: November 11, 2020, 10:26:34 PM »

Amen to both the heated grips as a good choice and the high degree of enthusiasm as something to avoid :huepfenlol2: :drink:
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acevtwin

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Re: Broken handlebars
« Reply #13 on: November 12, 2020, 08:50:44 AM »

I had the same thing happen to me with my 2004 SEEG. I thought mine was a fluke.
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porthole

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Re: Broken handlebars
« Reply #14 on: November 12, 2020, 10:21:41 AM »

I had the same thing happen to me with my 2004 SEEG. I thought mine was a fluke.


Seems to be not that uncommon.

45 minutes to disassemble - 4 hours to put back together.
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Proraver

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Re: Broken handlebars
« Reply #15 on: November 19, 2020, 08:13:45 AM »

10" wild ones with a single piece top clamp are installed. I managed to get everything fitted except the D%$# front brake hose. That will be here friday and then hopefulle we can get some seat time before sucky Ohio winter starts.  That last inch is really expensive.
« Last Edit: November 19, 2020, 08:52:08 AM by Proraver »
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ultra13

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Re: Broken handlebars
« Reply #16 on: November 20, 2020, 03:54:54 PM »

Proraver that figures. One thing holdin you up. Glad your happy with the WOs. We are heading out this evening for a dinner ride. Go Bucks!
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nolanfla

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Re: Broken handlebars
« Reply #17 on: November 21, 2020, 11:52:52 AM »

Can't answer your question about longer cables/wires (but I'm guessing you will need to extend what is stock) but make sure you use a one piece (full width) top clamp when you change them out.  Probably would have kept the stock bars from breaking.


mine did the same i put a pipe in them and ran the wiring on the outside it looks good
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nolanfla

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Re: Broken handlebars
« Reply #18 on: November 21, 2020, 11:54:26 AM »

I’ve seen that happen when folks use the handlebars as strap down points on a trailer. And yes, get a one piece top clamp.

I did the same with the upper clamp ,this is a Harley flaw for this year
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nolanfla

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Re: Broken handlebars
« Reply #19 on: November 21, 2020, 01:28:26 PM »

I had the same problem ,It's a Harley oops ,make sure you buy the top full bracket ,that was the issue ,the hole in the bars for the wires made it weak,tried to buy a used handlebar on ebay and they were all the same.
I cut the bars and I inserted a pipe inside the bars bought a new bracket for the clamp that went across this time.

only other change was having to put the wires on the outside of the handlebars,and had to cut the wires cuss the connectors would not go through the bars.I soldered and heatsink them back together and it took me about a week
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Cvostu

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Re: Broken handlebars
« Reply #20 on: November 21, 2020, 05:22:58 PM »

Happened to me in Daytona years ago on my O4.. Those stock bars were such garbage with the 2 piece clamp. I went with wild ones 12"and never looked back along with the one piece clamp.  :2vrolijk_21:Stuart
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spydglide

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Re: Broken handlebars
« Reply #21 on: November 21, 2020, 09:25:14 PM »

Happened to me in Daytona years ago on my O4.. Those stock bars were such garbage with the 2 piece clamp. I went with wild ones 12"and never looked back along with the one piece clamp.  :2vrolijk_21:Stuart
You never told me about my bars being due to failure Stu.  Now I'm worried. :nervous:spyder
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Cvostu

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Re: Broken handlebars
« Reply #22 on: November 21, 2020, 10:25:22 PM »

Spyder.  Change em before they go. Get the one pc clamp too.   You'll be glad that you did.  :nervous:Stuart
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Custom Dynamics turn signals.
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