Harley 1996-2006 PRE-WIRED Handlebar Installation Guide
- June 1, 2024
- Harley
Table of Contents
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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