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  #1  
Old 06-05-2013, 06:05 PM
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Wild 1 575 bars on my Ultra

I ordered up a set of these today for my CVO Ultra. It's been awhile since I had to extract wiring from inside a set of bars and run it into new bars. I know all the internal wiring pins are going to have to get removed from their respective connectors in the fairing so they can get pulled from the old bars.

How large a pain in the ass is this going to be?
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Old 06-05-2013, 06:19 PM
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It's not bad. Take pics of the connectors before you disassemble. Save some headaches and get the SE TBW sensor. I didn't even remove the sensor from my factory bars. Too much headache with the connector inside.

Under the fairing, depending on the height of your bars, you may need to relocate the connectors for the handlebar wiring down closer to the handlebar mount. I had to do that with the 12"rise on my bars.

I also changed the bushings to polyurethane bushings. Less of a rubbery feel.

Aside from that, new brake and clutch lines and you should be good.
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Old 06-05-2013, 06:23 PM
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Aside from that, new brake and clutch lines and you should be good.
Spoke with John at Wild 1 today, he tells me there is enough extra slack in the clutch and brake lines that the stock ones will fit fine. Hope so...

Also, the CVO bikes don't have the pain-in-the-ass green connector in the bars for the TBW, so that should make removal a lot easier.
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Old 06-05-2013, 06:25 PM
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That's cool. Then you may not have to move the connectors under the fairing. I do suggest the new TBW sensor though. Alot less headache. Part number is 32310-08.
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Old 06-05-2013, 07:14 PM
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Mike and I put 575s on the BSL. I don't see how you can get away with the stock length clutch and brake lines.
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Old 06-05-2013, 07:37 PM
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Mike and I put 575s on the BSL. I don't see how you can get away with the stock length clutch and brake lines.
Russ, that's why I questioned him about it. He swore up and down that there is enough excess clutch and brake line behind the fairing to do it. The 575 bars are about 2" higher than stock, correct? I'm not sure there's an extra 2" of slack to be had...
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Old 06-05-2013, 07:48 PM
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Yeah, I'm not seeing it.
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Old 06-05-2013, 07:57 PM
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Woody. The 575's should be 2 up and 2 back.

With the 05, wiring was no problem with he 575's.

I believe I went +4 on the clutch. Don't recall length on the brake, but I do remember installing new ones.
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Old 06-05-2013, 08:26 PM
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Woody. The 575's should be 2 up and 2 back.

With the 05, wiring was no problem with he 575's.

I believe I went +4 on the clutch. Don't recall length on the brake, but I do remember installing new ones.
Pretty sure there's enough extra wiring length. I guess I better round up a longer braided clutch and brake line before I tear into this...
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Old 06-05-2013, 09:08 PM
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Quote:
Originally Posted by Woody218 View Post
Pretty sure there's enough extra wiring length. I guess I better round up a longer braided clutch and brake line before I tear into this...
CVO, Hydraulic clutch right?

I've seen some posts elsewhere reference extenders for the hydraulic clutch.

Here are some part numbers I received from someone else who used them for their upgrade to mini apes. I have not researched any of these yet, but not sure why just the upper brake line can't be done without doing the lowers.

Hydraulic Clutch Line SCII 70" P/N: 1741-0314
Brake Line: Upper 3/8" 19" P/N: 1741-0781
Brake Line: Middle FLHT ABS CM2 P/N: 1741-1858
Brake Line: Lower FLHT ABS CM2 P/N: 1741-1857
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Old 06-05-2013, 09:20 PM
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Apparently the ABS brake hose is something whiz bang special. The dealer quoted me 400 bux for the longer brake hose setup. (!)
I have been told over on the cvo forum that there is no rhyme or reason to it but some cvos have different clutch hoses so you MAY need the clutch hose or you may not. For the 575s. If those prices are legit, the bar swap could run near a grand.... I need lots more info.
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Old 06-05-2013, 09:28 PM
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I could dig out the receipts, but I want to say that between the bars, the TBW sensor, the brake lines, and the clutch cable, I was into the bar swap for around $600.....You'd probably want to change the handlebar bushings too. Get it done at a shop, and you'd be looking at at least 4 hours of labor.
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Old 06-05-2013, 10:51 PM
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I'll do the work myself, so there's that. Now tell me why I need to replace the tbw? The CVO already has the version without the troublesome green connector. At least if I understood my "research". Is the tbw unit not reusable??

Once I get the RK finished, I can put the ultra in the cubby, I can pull the fairing to actually measure the hoses to see where I stand. There are those who claim to have done the 575s without longer hoses by simply rerouting the old ones. It's on the interwebs, so we know it's credible.
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Old 06-05-2013, 11:31 PM
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Hydraulic clutch, abs needs dealer intervention, wires need to be extended. Sounds like a royal PIA, maybe worth a grand to have the dealer do.

When I did the swap on my 2010 it was a pain seeing the colors on the wires. Make sure you have good light. I know when I was done I turned the radio volume up and the left turn signal activated. Had to go back in and figure out where I went wrong.

Also, Wild 1's told me there was no need to change clutch or brake lines. They lied. Turn the bars all the way to the right and the clutch would disengage.Do yourself a favor and get some 2-3" over lines and cables right off the bat.
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Old 06-06-2013, 05:42 AM
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575's on Ole Red, no way will stock cables or lines work. You will need front brake lines, throttle and clutch cables, if its FBW don't know.
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