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Sportster Motorcycle General Discussion and Problems For discussing problems about your Sportster motorcycle that don't fit anywhere else.

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Old 8th September 2020
awright2009 awright2009 is offline
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Default Grips/bars pinching wires

So, my bike was all together and running, but I noticed I must of broke my front brake switch, I always had problems with the right hand control Deutsh connector, so I figure buy a whole new chrome switch kit and finally fix that problem for good. Anyway, got the new switches and got things wired with new connectors. But when attaching the front brake I kept pinching the wires a bit and finally looked at how things were supposed to be routed.

So it looks like my grips might be like half an inch too short for the bars indention for the wire routing I think. Before I was probably pinching them, but the wires kind of lined up nicely where things looked tight. The new wires aren't quite as cooperative

Notice the bar indention, and the wires come out from the bottom on the housing, and should go up into the indent, but are instead being pinched by the brake clamp

https://i.imgur.com/T7VQehr.jpg


This is just my grips I have currently, some american iron horse ones, originally had some knurled chrome ones (harley I think) but after my crash a long time ago I just picked up these iron horse ones from ebay or some such, dont quite remember

https://i.imgur.com/NFY0WYW.jpg



So what do you guys think is the cause here, are the grips too short? The indention on the bars in the wrong place? The clamp missing some wire routing hole?


My plan of action is to grind out the clamp some to make a channel for the wiring, but figured if I can determine the real problem and fix it realtively easily maybe I should hold off on grinding so quick
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  #2  
Old 8th September 2020
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Toejam503 Toejam503 is offline
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Sportster/Buell Model: XL 1200 C
Sportster/Buell Year: 2006
Sportster/Buell Model #2: (Prev.Own)XLH Milw.Spec.
Sportster/Buell Year #2: 1981
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Maybe this sounds a little dumb, but you could always cut a 1/4"-3/8" off the ends of the bars to get the indents where you want them.
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Old 8th September 2020
awright2009 awright2009 is offline
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Hmm, I guess I could get a pipe cutter or a metal saw and take a bit off the ends, would have to mess with the clutch side too I suppose to make things even, but it surprises me that the bars are a bit short. I figure grip size is pretty standardized, I measured up to the switch housing with some calipers and got 123mm, a little extra is there for the throttle/idle cable ferrules, so I'm guessing it's the standard 130mm length one inch diameter
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Old 8th September 2020
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Toejam503 Toejam503 is offline
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Join Date: May 2010
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Sportster/Buell Model: XL 1200 C
Sportster/Buell Year: 2006
Sportster/Buell Model #2: (Prev.Own)XLH Milw.Spec.
Sportster/Buell Year #2: 1981
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Maybe you can get longer grips? It all depends on what brand the 1" bars are and what year they came from. Filing a slot in the switch housing is the simplest way but you really don't use the indents then.
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Old 8th September 2020
awright2009 awright2009 is offline
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I just picked up some new drag bars from J&P cycles for $30, which are cheaper than grips for some reason, I'll see if those work out with the grips I have, if not I'll start cutting / grinding on things. Hopefully I can get the clutch grip off without destroying it

These bars were on the bike when I bought it, so not too sure what the story is with them, but the dimples being in the wrong spot does explain quite a bit with the trouble I've always had getting them together over the years
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Old 4 Weeks Ago
awright2009 awright2009 is offline
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Got the new bars, figure might as well put new grips on there too, dimples look like they are in the right spot, the clutch side seemed like it was a bit too far from the dimple, but went together okay (I blame the after market chrome switch housing)

Get everything together and then I noticed that I must of destroyed my old handlebar bushings (probably been there since 1999) a bit of swing when the bars go left and right. So I look into how much those bushings cost and how to change them, not too bad really, $30 and some large bolts under the triple tree.

https://www.youtube.com/watch?v=6cRTLsoyS20

My bushings were completely dead, crumbled like cornbread, no rubber flexibility left at all. I must of crumbled it some ripping off the clutch side grip on the old bars. But I have some new ones on the way, and also a new front brake line as the new bars are slightly wider and the existing line seems a little tight

So the plan was to fix the sportster up, ride it for a bit, and sell it. Instead of buying a new bike. -- What ended up happening is I started to fix it up, bought a new bike, and am now continuing to fix it up before eventually selling it for probably slightly more than I paid in parts so far

https://docs.google.com/spreadsheets...it?usp=sharing

I'm at about $1,670 in parts and paid $5000 for the bike in 2008 or so, will be lucky to sell it for between $4,000-$3,500

But whichever 20 something year old kid eventually buys this bike will be very happy with it
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