DIY Network

Handlebar Restoration From "Classic Rides" episode DCLR-107

Figure A

Expert Harley-Davidson mechanic and resident DIY Classic Rides H-D guru Bill "Dunk" Dunkelberger joins host Kevin Tetz this segment to install new handlebars on the project ' 65 Electra Glide.

The original handlebars on the bike have seen better days, and there are some issues with the switches, which was mentioned and explained in earlier episodes. The bars work well in relationship to the high-mounted original seat, but since it's changing to a frame-mount seat, the handlebar will have to be changed as well to create a comfortable and natural riding position.

Getting Started

• Start by removing the clutch and brake levers (figure A). Loosen the retaining bolt, pull the pivot pin and remove the lever assembly.

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	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G

• Loosen the center handlebar mount bolts (figure B).

• With the battery disconnected, detach all the wires from the electrical panel so these wires can be fed through the handlebar mount.

  Tip: Be sure to make a wiring diagram (figure C) before disconnecting the wires so you can easily reconnect them the way they were.

• Feed the wires through the mounts and remove the handlebars.

  Note: The project bike had a one-piece bar that was cut and drilled for our application. By doing this, Kevin and Dunk could put a dedicated left and right turn signal on each bar respectively. There will be a well-labeled high-low beam switch (figure D), a horn switch and a stock-looking setup that will make the bike a lot safer to drive.

• Feed the left-side handlebar wires through the mount and tighten the mount bolt to secure the handlebar tube. Then assemble the right-side handlebar. Lubricate the wiring harness and feed it through the switch housing holes.

  Note: The new handlebars are stainless steel, which is perfect because they can be polished. Many custom handlebars are chrome plated, which can wear off in time.

• Pull the wire out of the end while you have help from someone who continues to feed the wire through the other end.

  Tip from Dunk: "What I like to do instead of pulling the wire all the way through to where the switch housing fits is to wrap it around (figure E). That way, if you ever have problems with the switches, you'll have the extra wire that you can adjust with."

• The right-side handlebar goes in the same way as the left. Feed the wires through the mount and into the electrical panel. Slide the handlebar tube into the mount and tighten the mount bolt to secure the handlebar.

• Go ahead and put on the carburetor control wiring, which consists of the throttle and the throttle return cables.

• Tighten the handlebar grip into place.

• Hook the accelerator cable sup to the carburetor. The cable slips into the carburetor fittings (figure F).

• The handlebar lever housing goes into place and is fastened to the new switch housing, securing both to the handlebar.

• Cut off the excess wiring harness and cut back the black shielding.

• Use a wire stripper to remove the insulation, and attach the terminal connectors, crimping them into place (figure G).

• Following the wiring diagram, hook up the wires. For the project bike the white and gray wires are connected to the #8 terminal. Tighten the connection down.

• Continue connecting the wires according to the diagram.

In the final segment the wires will be run to the back of the bike and the electrical system will be completed.

RESOURCES :

The Eastwood Company

The Eastwood Company is a supplier of automotive-restoration parts, tools and supplies.

The Easthill Group, Inc.
The Eastwood Company
Website: www.eastwoodco.com

Restoration Parts (Custom Chrome)
Custom Chrome
Website: www.customchrome.com

Motorcycle Restoration Parts (In the Wind Motorcycle Parts)
In Wind Motorcycle Parts
508 Lovell Rd.
Knoxville, TN 37932
Phone: 865-560-5650 or 865-777-0884
Fax: 865-777-0886

Norton Abrasives

Sandpapers, cleaners, abrasives and bodywork supplies.
Website: www.nortonautomotive.com

Auto Body Color and Supply
Phone: 615-726-0361 (Nashville Store)

Motostorm Chrome Paint
Website: www.motostorm.com

Also available through Innate Technologies (see contact information, below, under the Guest entry for Nate Chase).

Keller Wallace Street Rods
6340 Clinton Highway
Knoxville, TN 37912
Phone: 865-680-3623

GUESTS :

William "Dunk" Dunkelberger
Restoration Coordinator / Mechanic
Harrly Hoggs & Piggletts
1409 Piney Rd.
Maryville, TN 37803
Phone: 865-681-7699
E-mail: hoggsandpiggletts@yahoo.com

Nate Chase
Automotive Painter and Designer
Innate Technologies
PO Box 540691
Omaha, NE 68154
Phone: 702-651-6551
E-mail: E-mail: sales@innate.com
Website: www.innate.com