I've finally got motivated to start tinkering with the Street Bob, first cab off the rank was to internally wire the bars. I just missed out on having this done by the factory as I got an 08 and not an 09 which come with internally wired bars. But I still prefer the 08 over the 09. So I decided to make it easy for myself and just buy some 09 bars which already have all the slots for internal wiring. While I was at it I though I'd move the front indicators to the forks as well. Hardest part of the whole job was getting the wiring out of the frame and getting the Deutsch connectors off. But in the end all was pretty simple. See pics below. End result looks much cleaner I reckon. I thought I'd write a bit of a guide to help others thinking of doing the same thing.
Here's the before shot with fugly wiring and indicators in the usual place:
First step was to remove the plastic cover on the underside of the frame just below the neck. I was lazy and didn't remove the crossover hose on the tank which would've made it easier but I still managed to remove the cover without touching the tank:
Once I got the bundles or wiring out of the frame, I looked for the two Deutsch connectors that wire the left and right hand controls. The left one is white and the right hand side one is black:
I took close up shots of all the wire positions before taking all the wires out of the connectors:
I also located the smaller left and right indicator connectors, right one is black and left is white:
I removed all the pins from the Deutsch connectors. This is a four step process:
1) Remove the little plastic clips on the back of the connectors 2) Remove the rubber dust shield from the inside back of the connector 3) Inside the front of the connector where the pins are, you'll notice a white plastic cover below the pins. In the centre you'll notice two small holes, this plastic cover needs to be pulled out about 5mm. This can be done by using long nose pliers inserted into the two small holes in the centre. 4) Once that is done you'll notice some ever smaller holes in front on each pin inside the front of the connector. The pins can be removed by inserting a straightened paper clip wire into these holes. You'll feel a click when you insert the wire and then the wire can be removed from the rear of the connector. I actually found that some of the wires wouldn't come out from using this method through the front, so the same method can be used from the back of the connector, ie inserting the paper clip wire into where the wires are from the back. I got most wires out easier from the back!
Next was to get the wires out of the indicator connectors, this can be done using a small skewer and sticking that into the front of the connector:
Once I freed up all the wiring from the connectors I was able to easily put the wiring through the frame and also off the old bars. The new mini-ape bars for the 2009 Street Bobs have pre cut slots for all the wiring. Piss easy to get the wiring through the bars.
It's a little more difficult to get the wiring back through the frame, but not too hard. Once I was done with setting up the switch housing and levers on the new bars, I re-assembled all the wiring the the connectors.
Finished product:
don't know if I should laugh or cry Dazza me old mate.....
I'm fitting different bars to my 08 Rocker. The right side switch connector block,6 wires, and no plug type written on plug, (whether it's deutsch or whatever) I put the fine longnose in the small holes in the female side of plug but plug won't come apart. It moves about 5mm but stops. Should I be a bit more forceful? Should I post pics if possible?
Sorry misunderstood with my first reply. When you pull on the inner part of the plug with the pliers, it will only move about 5mm, that is correct, it won't come out. You need to move the inner part of the plug first then remove the wires through the back. To remove the wires you need to use the method I posted above.
First wire's out! Thanks KC. (Used a thin jewelers s/driver like ya said) Merry Christmas and a bonza New Years as well.
Kingchops
Thanks for your thread came in very helpful.
Regards
Black1
Yeah thanks choppies. I fucked up anyway. I bent the needle points on the connectors,tried straightening them out and snapped em off! After attacking job again 2 days later after I simmered down, I found about 60cms of wires still in the handlebars. GRRRRRR!!!!!!!! Pulled it out and then had to drive near 2 hrs ( local shops no go) to a HD shop for genuine electrical pins. 1 pin per gen HD packet at 80c each. Only available from HD. Local auto lekkie couldn't get em. Backyard mechanics (wannabe's)....................Live and learn
Just make sure they are new late model bars with holes that are big enough for the wiring!!! What a cunt of a job But,us backyarders gotta learn somehow. Not by choice either.
that was yesterday Beags
