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Discussion Starter #1
I modified my levers the other day using a bench grinder, files, sandpaper, drills and polish. Put the bars on last night. Internal wiring is a major PITA.



 

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Nice! Those were the pictures I've been waiting for. Now for the Questions: Did you have any problems running the wires internal since they are 1" bars and did you have to extend any wires or cables?
Thanks in advance!
 

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Height too please.
 

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Discussion Starter #4
I believe the inside diameter is the same for 1 inch bars as 1 1/4 inch. Plenty of wire, and I didn't even have to reroute the clutch or brake line. I separated the wires from the connectors behind the fairing (make sure you document what order they go in) then cut the factory loom just beyond where it enters the opening on the bars. Then I separated the wires by what row they were in the connectors, so I ended up with 4 different "looms". I wrapped each "loom" of wires with electrical tape and that was much easier then when I tried feeding 2 larger looms through. I also unconnected the TBW connector behind the fairing, fed it back to the original handlebars, then pulled the twist sensor our until two smaller connectors appeared. Unhooked this, then installed it in the new bars in reverse order. This way you don't have to unplug these wires from their connector. (this is explained better in another post) If you review all the posts under "Handlebars and Controls" you can probably answer any question you have. This forum is full of valuable information.

These bars are 9 inch, and are in stock. You can special order any length, but Chainsaw posted that he special ordered bars from these guys and had a difficult time receiving them. We have a height limit in Maine, and I didn't want to exceed it. I'm 5'9", 31" inseam, running a Badlander seat and the height is perfect.
 
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Very nice look. Love the chrome spikes you added and the lever hole design matches the holes in the gussets of the bars. Very clean...
 

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Discussion Starter #9
thanks.

Thanks all. Complements coming from you folks mean alot. Once you touch the lever to the bench grinder ain't no turning back. But to quote someone else on this forum, "Why should I pay someone else to fuck up my bike when I can do it myself."
 

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Discussion Starter #10
Meant to mention, the local Harley mechanic gave me a 2 into 1 Thunderheader exhaust off of a bike that went down. Have to do a little bit of cosmetic repair on the "muffler" section, but I plan on putting that on this winter. I have to weld in some O2 sensor bungs and I plan on wrapping the header section back to where the muffler starts expanding in heat wrap (did that on my rigid and love the look) and painting the muffler section high temp black. I already have the wrap and paint but I think I'll wait til the winter months so I can take the stock one off, fit the new used one, then do the modifications when I won't be hurried.

Can't wait to cure the anemic sound coming from it.
 

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I agree, the levers are the sh*t!!

I have the same bars, and had mine straight up as well, had to bring down though as there was not enough pullback at that height to be comfortable....

Show us what she looks like when u get the thunderheader installed!;)
 
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