Models with heated hand grip wiring: Cut and remove the unused heated hand grip two-pin connectors from both ends of the harness.
Wrap wire terminal ends from each source in tape to make separate leaders. Wrap each leader tight enough to enter and pass easily through the new handlebar.
Label each wire bundle (left or right) to help make sure that wires are routed properly.
Guide strings (or thin wires) aids in the routing of the wire bundles through the handlebar.
See Figure 1. Stagger the pins (1) so they are not in the same locations along the harness (2). See Figure 2. String a suitable cord (1) through the handlebar. Tie the cord to the wire harness. Wrap tape (2) over the harness and pins. Tape should come to a taper (3) and be flexible to ease pulling through the handlebar. Pull the cord through the bar to route the wire bundle to the proper exit point.
Figure 1. Pins and Wire Harness
Figure 2. Pull Cord and Wire Harness
Apply a light coat of liquid soap, window cleaner or all-purpose lubricant to the right side switch wire bundle.
See Figure 3. With the handlebar placed on a smooth, soft surface, grip ends upward, gently feed the right side switch wire bundle into the opening on the underside of the new handlebar and toward the large opening in the center of the bar.
Carefully pull the wires through hole in handlebar to prevent stripping the wires. Stripped wires can cause short circuits and damage vehicle electrical components, which could cause loss of vehicle control resulting in death or serious injury. (00418b)
Pull the wire bundle through the exit opening in the center of the handlebar. Bring the switch housing into approximate final position. DO NOT fasten the switch housing to the handlebar now.
Repeat Steps 3 through 5 with the left side switch wire bundle, and both turn signals, if needed.
Figure 3. Switch Housing Wire Routing
Remove the tape from the ends of the wire bundles.
Check for electrical continuity between the handlebar and each wire in the wire bundles. Continuity indicates a short circuit, which requires examination of the wires and routing in the switch housing.
Verify that the ignition/light key switch is turned to OFF. Install main fuse.
Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)
Turn the ignition/light key switch to IGNITION, but do not start the engine. Test all switches and lights for proper operation.