Trystan Casey
Replacing handlebars on an Electra Glide motorcycle is a task that can be done at home, although it may be time-consuming. It is recommended that you refer to the shop manual for instructions. The process involves removing the seat, disconnecting the battery, and removing the dash, gas cap, and radio. The handlebars can then be removed, and the wiring can be disconnected. New handlebars can be installed, and the wiring can be extended and reconnected. Finally, the hand controls and hand grips can be reinstalled. The cost of replacing handlebars on an Electra Glide can vary depending on the specific parts and modifications required, but it generally ranges from a few hundred dollars to over $600.
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What You'll Learn
Handlebar height regulations and local laws
When replacing handlebars on an Electra Glide, it is important to consider the handlebar height regulations and local laws that apply. Most U.S. states have restrictions on the height of motorcycle handlebars to ensure safe riding. The most common law, which is applicable in most states, restricts riders from installing handlebars that are more than 15 inches above the seat height when the rider is seated. However, it's important to note that handlebar height regulations can vary between states. For example, in Georgia, the maximum height restriction was amended to 25 inches in 2016, while Nebraska prohibits handlebars from exceeding 15 inches above their mounting position.
The basis for these laws is to ensure safe riding and proper control of the motorcycle. Excessively tall handlebars can restrict the rider's vision and make handling, steering, and turning corners difficult. They can also force the rider to sit in an uncomfortable position, affecting their ability to operate the motorcycle effectively. While some motorcyclists argue that these regulations limit their comfort, the laws aim to balance rider comfort with public safety.
When replacing handlebars on an Electra Glide, it is crucial to refer to the specific laws and regulations of your state or region. This information can typically be found through local government websites or motorcycle associations. By understanding the legal requirements, you can ensure that your new handlebars comply with the height restrictions and other relevant standards.
In addition to legal considerations, it is important to take into account the practical aspects of handlebar height. The ideal handlebar height should provide a comfortable riding position and allow for easy reach without straining your back or arms. This may vary depending on your height and arm length. When choosing new handlebars, consider the distance and height that best suit your body type and riding style.
Furthermore, when modifying your Electra Glide, be mindful of the potential impact on other components, such as cables and wires. As mentioned in some forum discussions, changing the handlebar height may require adjustments to clutch cables, brake lines, and throttle cables. These additional modifications can incur extra costs and complexity, so it is advisable to consult a professional or refer to a reliable manual before proceeding with any handlebar replacement or adjustment.
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Removing the seat and battery
Removing the Seat:
- Start by locating the screw at the back of the seat, where it attaches to the rear fender. You may need to open any attached tour pak or storage compartment to access this screw.
- Use a small screwdriver to remove the screw. If your seat has a strap, you will also need to remove it.
- Once the screw is removed, carefully lift the seat. Place your hand between the seat bracket and the inside of the tour pak to prevent scratching as you lift.
- Slide the seat towards the back, towards the tour pak. With a little wiggling, the seat should come off.
Removing the Battery:
- Before removing the battery, it is recommended to check the condition of the battery cables. Ensure both ends of both battery cables have a clean and tight connection.
- If your Electra Glide has the original battery and it's been more than 5 years, consider replacing it.
- To remove the battery, start by disconnecting the battery cables, being careful not to short circuit the terminals.
- Loosen any clamps or brackets holding the battery in place, and carefully lift the battery out of its compartment.
Remember to take appropriate safety precautions when working with motorcycle components, and always refer to the official manual or seek professional assistance if you are unsure about any steps.
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Disassembling handlebar wiring
To disassemble the handlebar wiring, you will need to remove the wires from their harness clips. This can be done with a flathead screwdriver. Once the wires are removed, take off the insulation from the plastic housing. Next, unlock the pins inside the housing. A dedicated de-pinning tool is recommended for this step, but a heavy-duty paperclip can also be used.
After the wires are released from the housing, you will need to pass a high-strength cable or wire through the bars. Attach the handlebar wiring to this cable and use it to pull the wires through the bars. This step can be frustrating and may take several attempts.
Once the wires are routed through the handlebars, you will need to extend them to match the length of your new handlebars. You can use a handlebar wiring kit or your own wiring and components. Match each stock wire with its corresponding wire from the kit and snap them together. Finally, snap the wires back into their appropriate housings.
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Installing the handlebars
To install handlebars on an Electra Glide, it is recommended to have the motorcycle centred on a jack. You will also need a collection of tools to remove the bike's handlebars. First, remove the seat by taking off the rear seat screw. Disconnect the bike's battery to ensure safety and protect the bike's electrical system. Remove the side cover to access the battery compartment underneath the seat. Then, remove the dash by first removing the bolt at the bottom of the dash and then removing the screw at the top of the dash. Next, remove the gas cap to allow the full removal of the dash, and then reinstall the gas cap to prevent debris from falling into the gas tank.
Now, remove the radio from the inner fairing, then loosen the handlebar clamp cover and completely remove the handlebars from the motorcycle. Begin to disassemble the handlebar wiring by removing the wires from their harness clips. Use a flathead screwdriver to release the clips. Then, remove the insulation from around the plastic housing. You can use a dedicated de-pinning tool or a heavy-duty paperclip to unpin the wires. Next, unlock the pins from inside the housing.
To pass the wires internally through the bars, pass a high-strength cable or wire through the bars. Attach the handlebar wiring to the cable and use it to pull the wires through the bars. After the wires are together, slide over the heat shrink and then collapse the shrink tubing by applying heat. Once the wires are extended, snap them back into their appropriate housings. Finally, reinstall your hand controls, hand grips, and battery.
Note that the installation of some handlebars and risers may require a change in clutch and/or throttle cable and brake lines for some models. Handlebar height is regulated in many locations, so be sure to check your local laws to ensure your motorcycle meets applicable regulations.
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Cost of replacement
The cost of replacing handlebars on an Electra Glide can vary depending on the specific parts and modifications required. According to a user on the V-Twin Forum, the total cost of replacing their handlebars, including grips, brake lines, clutch cable, transmission gasket, brake fluid, and gear oil, amounted to $620.34.
The cost of individual components can vary, but here is a breakdown of the prices mentioned in the forum:
- Handlebars: $224.95
- Grips: $79.95
- Lower brake line: $129.95
- Upper brake line: $64.95
- Clutch cable: $99.95
- Transmission gasket: $5.15
- Brake fluid: $6.95
- Gear oil: $8.49
It is worth noting that some users have mentioned extending wires and cables, which may incur additional costs. For example, one user was quoted $1200 for 13" apes when considering anything longer than 2 inches.
If you choose to install the handlebars yourself, you can save on labour costs, as mentioned by some users who have performed the replacement themselves. However, if you do not feel comfortable with the procedure, it is recommended to seek professional assistance, which will add to the overall cost of the replacement.
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Frequently asked questions
Replacing handlebars on an Electra Glide can take anywhere from 45 minutes to two days.
You will need a motorcycle jack, a flathead screwdriver, a heavy-duty paperclip or de-pinning tool, a 3/4" 6-point shallow socket, a 1/4" allen wrench, a 3/16" allen wrench, a 5/32" allen wrench, a tube of blue threadlocker, and a high-strength cable or wire.
First, centre the motorcycle on a jack and disconnect the battery. Then, remove the seat, the dash, and the radio. Loosen the handlebar clamp cover and remove the handlebars. Disassemble the handlebar wiring, and remove the insulation from the plastic housing. Unlock the pins from inside the housing and pass the wires through the bars. Finally, extend the wires and snap them back into their housings, then reinstall the hand controls and grips.
Be careful not to damage the fragile handbrake lever button during reassembly. The installation of the chrome skirt on the front forks is also noted as being particularly difficult.
You can find the Harley-Davidson Handlebar Installation Requirements document on the Harley-Davidson website.
