|Prepping the Patient!|
Adding to it all was the discrepancies I was getting in prices for a new brake and clutch hose. Moto-Sport Newman on the South Shore wanted to charge me $300.00 for the two lines including fittings. The same store, but in LaSalle wanted to charge me $275.00 for the same lines! Finally, L'Amis Denis Honda in Lennoxville, Sherbrooke actually wanted to charge me $150.00 for the two lines! None of these quotes include labor or installation costs. I nearly went with the latter but after two to three months of trying to figure out what will or will not work on my bike I decided to just throw caution to the wind today and bite the bullet! Installing the new bars was actually really easy to do and requires nothing more than proper preparation and planning. This blog will show you how to install a set of Wild 1 Chubby Outlaw 10 inch Z Bars using stock (OEM) brake and clutch hoses! I will also show you how to install new (old stock) Harley-Davidson Vintage Gran Turismo Grips. You will need the following items to pull this off:
- Scotch Tape
- One Pen
- One Phillips Screw Driver
- Allan Keys
- One Shoe Lace (really...)
- A Vacuum Cleaner (stay with me...)
- Lock Tite (Blue)
- Crazy Glue
- Bit of Luck....
After covering your tank (avoid unnecessary dings) begin with the headlight.
Remove headlight and expose internal wiring.
BEFORE disconnecting anything, LABEL EVERYTHING!
Disconnect everything carefully. Disconnect one at a time.
You need to give a small tug, nothing more.
I used numbers because I can count. :-p
You can use letters, names, roman numerals, Shakespearean quotes...
Just be realistic about how much you can write on a piece of scotch tape!
Remove the back plate of the headlamp.
This is a must as it is what holds the cables securely in place.
Place back plate and screws some place safe.
As you can see you can simply pull the control cables out gently and place to the side.
Repeat for the other side.
At this point, your headlight is off, your cables disconnected and labelled,
and the wiring is no longer in the bucket of the headlight!
Remove the Chrome Caps on the risers.
They are made out of plastic so be careful not to crack them.
Remove the Chrome Caps on the lever and mirror mounts.
Riser View After Cap Removal.
Remove the four bolts with an Allan Key!
Lever and Mirror Mount View After Cap Removal.
Remove the two bolts on each side of the bike with an Allan Key!
Do NOT pull mounts off
until you have carefully removed the connectors on each side.!
Place the Clutch and Brake Lines with attached mounts gently over the front of the bike/
Before you can remove the bars remember that the Throttle cable needs to be removed first!
Remove the screws on each housing.
Be careful with the throttle side as it also houses, well, the throttle cable!
There is a support bracket below the throttle and kill switch housing.
Remove the screw and leave it where it is. It cannot go anywhere else.
When opening the housing unit disconnect the throttle cable!
Take note of which section the throttle cable came from.
(Second hole Closest to my Finger!)
This is what everything should look like by now!
Gently pull the bars up.
Slow and Steady, remember you don't want your classification system
a la scotch tape to get ripped off in any way!
Time to reassure you patient everything will be OK!
Total time, from start to finish: 45 Minutes TOPS!
Unless you are lucky and have an indoor garage,
I suggest you put a bag over your headlight bucket to keep the elements out!
Time to pull the wires out!
Again, do so gently so not to accidentally rip off your taped classification system!
As you pull from one side feed the other end gently and take your time.
Set your cables to the side and prep for installation into the new bars!
You will have to DRILL replacement holes to secure your Switch Housings!
Depending on what year Intruder 1400 you own you may or may not
have to do the same thing on the bottom of your new bars
in order to fit the stock (OEM) risers!
IMPORTANT: Tie a Shoe Lace to the tip of your wrapped up wires!
This makes the next step as easy as bumble berry pie... mmmmm, pie.
I have read various tips on how to go about running wires internally.
Some have used magnets, others wire.
Personally, I opted for a VACUUM CLEANER!!
It'll suck that shoe lace right up!
Handlebar Grips are easy enough to install
but here is a quick guide to how do so in case you never have before.
Remove the cap ends on each side of the bar.
Just give them a good hard twist and tug! ;-)
The left hand side is far less complicated.
You will need Ultra Bond or some other sealant. Apply generously and slide into place and hold.
I wanted to use the stock (OEM) chrome end tip that the original grips had.
So I heated the left hand grip.
Than I inserted the chrome end tip.
This finishes off both sides of the bike nicely and is now mirror image of one another.
This is a personal preference, thus, feel free to skip Step 34 and Step 35 if you wish!
Thank your wife
(or husband, as the case may be...)
for helping out and have her pose with the completed project!
Install your handlebars on your risers. I am using stock risers.
Also, start to replace your bits and bobs such as clutch controls, switch housing, etc...
Use Lock Tite for added security.
Replace the right hand side throttle cable in the appropriate slot
(remember, second one closest to the front of the bike - or my thumb, as the case may be!)
Replace Chrome Caps on Riser Nuts
Replace Chrome Caps on Mirror Mount Nuts
Time to Re-Connect the Wires!
Slide Wires through the back end of the bucket via the rubber grommet.
As much as possible, organize the wires so that they
do not get entangled as you begin to reconnect everything!
The last piece to reconnect is the headlight!
It doesn't hurt to have a little helper!
If you find you have one (1) extra of these, don't despair.
Think back, there was an extra one when you started.
Replace the back plate on the headlight bucket.
Voila, Admire Your Handiwork!
My Son is Particularly Pleased with his Contribution!
Pretty Damn Cool, if you don't mind my saying so!
My Son Approves!
(or is constipated, not sure which... :-p)
I'd like to end this particular blog by dedicating it to the folks at Intruder Alert! In particular, I wish to thank the following people for putting up with my endless questions over the course of the last few months. They really didn't have to be so darn nice to a total stranger. Nor did they have to answer my questions over and over again without fail. Their advice, sympathy and expertise gave me the know how and courage to grab the bull by the horns and get to it. So thank you Griph, Tiny75, and bigt7088. I would also like to acknowledge bigskyintruder's original thread on how to swap your handlebars which was equally as invaluable. If I forgot anyone in particular I am sorry but thanks does go out to the entire community for their help and support.
Oh, and thank you to my wife, son and my pooch, Baxter for all their help today!