Harley 1996-2006 PRE-WIRED Handlebar Installation Guide

PRE-WIRED
Handlebar
for 1996-2006 Electra Glide Models
INSTALLATION INSTRUCTIONS

Note:
Before proceeding, refer to your motorcycle manual and consult a certified mechanic if necessary. Safety is paramount!

Removal of Original Handlebar:

• Optionally, remove the windshield.
• Disconnect brake and clutch lines following your motorcycle manual.
• Slide off both grips.
• Remove mirror mounts, switch housings, and the clutch lever assembly.
• Loosen the riser clamp bolts and remove the old handlebar.

Wire Connection for New Prewired Handlebar:

First of all, take a second to inspect how your handlebars are set up when they arrive. All of the wiring harnesses (including CAN-Bus and Turn Signal Wire Harness) are prewired, precut, and have PLUG & PLAY connectors preinstalled at one end, with color-coded wires grommet at the other end.

Please refer to the following steps to complete the re-connection of the Color-coded Wires:

• Take a photo for the color-coded old wires before re-connection.
• With the wires now cut and stripped, begin placing them into the pre-soldered heat shrink connectors, matching the colors one wire at a time.
• Connecting the wires base on the photo you took before, make sure that the copper wires on both sides are tightly connected. This ensures a proper connection before heating the connector and melting the solder. Continue putting the wires together one by one.
• Then, also one wire at a time, heat the pre-soldered heat shrink connectors with your heat gun, keeping each connector as isolated and stationary as possible.
• Heat the solder inside each connector until you see it liquefy/melt, then remove the heat and keep the wire stationary for another 5 seconds or so to allow the connection to cool and harden. Repeat for all of the other wires.

Installation of New Handlebar:

• Install the handlebar, guiding the wire bundles down through the upper fork bracket.
• Seat the handlebar with the knurled area centered.
• Install the riser clamp and bolts but keep them loosely tightened.
• Adjust the handlebar angle to run parallel to the front forks.
• Tighten to Torque: 17-21 N.m.

Hand Control and Housing Installation

Note: If opting for a taller handlebar, consider longer lines and wires.

• Install throttle cables and the right grip/throttle assembly.
• Install switch housing and brake lever assembly. Consult your motorcycle’s owner’s manual or seek help from a certified mechanic if needed.
• Verify that the right grip/throttle sleeve rotates freely.
• Install the left handlebar grip.
• Install switch housing and clutch lever assembly. Refer to your motorcycle’s owner’s manual.
• Install a sufficiently long clutch line and connect it.
• Install the brake line according to your motorcycle’s owner’s manual.

Electrical Connection

• Reattach all electrical components removed in Step 1.
• Ensure all pins are attached and test turn signals, brake lights, and other electrical components.

Safety Check:

• Ensure all wiring and cables are secure, and nothing is obstructing the bike’s mechanical parts.
• Test the brake to ensure it’s working properly.
• Test turn signals and press the brake to check the brake light.
• Move the handlebar from left to right and back to ensure smooth movement without obstruction.

WARNINGS!

• Do not proceed if you’re unsure about the steps. Consult local dealer.
• The product provider is not responsible for any damage or injury resulting from improper use.
• Ensure no part of the product obstructs your bike’s functioning.
• Follow these steps, and you’ll be back on the road in no time! Stay safe out there!

Technical Support Email: customerservice@prewired.top

Documents / Resources

| Harley 1996-2006 PRE-WIRED Handlebar [pdf] Installation Guide
1996-2006 PRE-WIRED Handlebar, 1996-2006, PRE-WIRED Handlebar, Handlebar
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