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[North Georgia Hawg]

Tedious and time consuming....2 cigars and 4 beers, I recall...

I need the extra length lines I ordered, glad you have enough...I think HD has a plus or minus "whatever" length you need of 2 inches...

Worth it.

How many cigarettes = 1 cigar? If it's a pack, that seems about right!

CHUBBIES HAVE ARRIVED! Unfortunately I have to work until evening before I can start on the "fishing expedition" tonight...

[Midnight Rider]

How many cigarettes = 1 cigar? If it's a pack, that seems about right!

CHUBBIES HAVE ARRIVED! Unfortunately I have to work until evening before I can start on the "fishing expedition" tonight...

Yea...one pack of regular cigarettes.  If you don't have something specific to do it, Windex works pretty well for lubing up the wire sheathing before putting it back in.  Make SURE all the pins are seated well in the connectors!!

[480Ruger]

My clutch cable was routed through the fairing bracket instead of under it.  Made it a little tight but didn’t need to change any cables.  Much more comfortable to ride now.   I picked up a set of the poly bushings but was told by a few people that they set the bars up just enough so the switch cover won’t line up under the inner fairing.  Haven’t tried so I don’t know for sure. X2 on the connectors!

[Rhodsman]

North Georgia Hog, Killer Bike. Love the especially the custom Corbin, and windshield. Passing lights aren't for me, but they look great on your ride. Nice work.

I did the Chubby 577. LOVE them, but did have to re-do cables. Well worth it.

[North Georgia Hawg]

My clutch cable was routed through the fairing bracket instead of under it.  Made it a little tight but didn’t need to change any cables.  Much more comfortable to ride now.   I picked up a set of the poly bushings but was told by a few people that they set the bars up just enough so the switch cover won’t line up under the inner fairing.  Haven’t tried so I don’t know for sure. X2 on the connectors!

Yeah, my clutch line is routed through the fairing bracket as well... can't believe they do that.  I also did not want to disconnect the clutch line nor brake line from their hand controls, to avoid having to bleed the lines when I put everything back together. SO, I couldn't completely detach the inner fairing from the bike, and it is sitting on a big pillow on the front fender, with the hand controls sitting on a towel on top of it. It's not going anywhere, so no worries there. But everything looks a total MESS right now...

Finally finished work for the day, and am about to embark on my "fishing expedition" now... Wish me luck! I'm thinking that fishing a small wire through the Chubbies, and tying it to the other wires and pulling them through that way will make it a lot easier.

 

Thanks for all the words of encouragements, gents! With any luck I'll have her all put back together before I hit the sack tonight! That would make my whole week!

[FAST380]

NGH,

you should be good to go, sounds like you are on the right track. I did reroute my clutch cable a little, moved some of the zip ties down by the master cylinder, and also re-did the bracket at the neck where the brake lines and clutch lines go through. I ended up putting the clutch line through the lowest point on the bracket and moving the brake lines up one notch. Kind of hard to explain, but if you look at it you should see what I am talking about. This gave my clutch just that little extra that made me more comfortable.

Good luck, you will be happy.

[backroad Mike]

Finally finished work for the day, and am about to embark on my "fishing expedition" now... Wish me luck! I'm thinking that fishing a small wire through the Chubbies, and tying it to the other wires and pulling them through that way will make it a lot easier.

If that doesn't work try a piece of twine or light line and a compressor to blow the line through the bars then attach and pull the wires through. 

[North Georgia Hawg]

Yea...one pack of regular cigarettes.  If you don't have something specific to do it, Windex works pretty well for lubing up the wire sheathing before putting it back in.  Make SURE all the pins are seated well in the connectors!!

One pack (1 cigar) down... one to go! I sprayed the entire length of all of the wire bundles with WD-40, and my wife tugged gently on the receiving end while I pushed and wiggle the bundles gently from the other end. Took about 30 mins to get everything in the Chubbies.

UPDATE: All wire bundles are in the Chubbies now!   

Now on to reassembling the wire pins back into the Deutsch connectors... hopefully each in the right place. I'm tracking to plan well but I expect Murphy will be along soon... he usually shows up right about this place in every project!

[North Georgia Hawg]

North Georgia Hog, Killer Bike. Love the especially the custom Corbin, and windshield. Passing lights aren't for me, but they look great on your ride. Nice work.

I did the Chubby 577. LOVE them, but did have to re-do cables. Well worth it.

Thanks a lot, man! It's become a labor of... umm... OBSESSION???

[North Georgia Hawg]

It's Beginning to Look a Lot Like... a MOTORCYCLE again! Just looking at the Chubbys on the bike... I KNOW I'm gonna LOVE 'em!



 

[PASN YU]

It looks like it's starting to come together. 

[Midnight Rider]

I hate to tell you this now, but you didn't have to move the entire inner fairing, just the lower inner...

[BUCKNUT GREG]

I hate to tell you this now, but you didn't have to move the entire inner fairing, just the lower inner...

RUTRO 

[North Georgia Hawg]

It looks like it's starting to come together. 

YEP! Everything's back together. Just have the fairing skirt and outer fairing left to go... then an hour of polishing off all of the oily fingerprints.   

Murphy DID finally show up last night, BTW...    

I thought I was being super careful in documenting all of the the wire positions, but made one error on the Twist Grip Sensor (TGS) connections. There are two little wire bundles that come from the TGS - both with one black, one red, and one white wire. One of the bundles is encased in yellow plastic, and the other is encased in black plastic. I had documented where the three wires go - but DIDN'T think to document  which wire bundle went in which bank of the connector. Of course, I got them wrong. I put the wires from the black bundle where the wires from the yellow bundle should have gone, and vice-versa. 50-50 chance, and I lost... just like I always do in LA$ VEGA$. So, the bike would turn over, but wouldn't start. I unplugged the TGS connector, and the bike started up fine.
So I sez to myself, "Self, you got yer WIRES crossed!"     Under 10-minute fix to pull the 6 TGS wires from the connector and put them in their proper places. Not bad, as projects go! 
Haven't had time to take the bike out for a spin yet... but just sitting on it, the handgrips are now in the PERFECT position - no more stretching to reach them comfortably!  They look beautiful, too... I love the fat, beefy look! 

But the best thing was... NO NEW LINES NEEDED! Plenty of room to go stop-to-stop with the stock ones! 

Thanks for everyone's input, suggestions, and moral support! Now where did I put that cigar???

[North Georgia Hawg]

I hate to tell you this now, but you didn't have to move the entire inner fairing, just the lower inner...

Well, I had to move the inner because the crossmember part of it, under the radio opening, was sitting right on top of the rear Torx #40 bolts that hold the bars on, and I couldn't get to them until the inner was out of the way. Anyway, I learned a lot about all the stuff that's in there, and what all those myriad connectors connect.

Oh, it's BEER-THIRTY! Gotta go!