This picture shows the throttle assembly. Note the green plug. Because we are using an earlier style bar, the green plug presents a problem. In this case we chose to replace the Throttle By Wire system with one from a CVO model that doesn't use the plug.

Here is a picture of the inside of the early style bars. Because of the indent for the wires, the green plug doesn't fit. The CVO throttle assembly resolves this issue.

Another problem is the length of the handlebar from the indent for the wires to the end of the bar. This picture is the new style bar.

This picture shows the old style bar and you can see the throttle assembly won't fit. The bar is not long enough to accommodate the new throttle assembly.

 

To correct the problem with the handlebar length we choose to lengthen the bar. To do this, we took the stock bar and cut the end off. In the previous picture we marked the throttle assembly with a sharpie and used it for measuring.

Here is the stock bar end with the notches for the throttle assembly.

After measuring we cut the bar end off.

This picture shows how much we are extending it.

After lining up the bar end and tacking it in place, we test fitted the throttle assembly before final welding.

Here is the bar end welded on.

After welding we used a burr to smooth out the weld inside the bar.

The out side was carefully ground smooth and sanded to remove sharp edges that could possible catch the grip.

The new CVO throttle assembly was then reinstalled into the bar.

 

Because the bars used were 1.5" it left a step in the bar that would not normally be seen. Since we matched both sides of the bar, it was on the clutch side as well. The owner filled in these areas with leather strips cut to fit.

Here is a picture of the new bars installed.

 

Sweet job!.. I was wondering what the new system was made up of. Thanks for the post..:clap:

 

Great informative post. Just wondering, how many hours of labor?

Bwana01

 

About 8 hours...including installing the switch housing wires inside the bars (and extending the wiring) and doing the brake lines, clutch cable. The bars were actually 1.5" diameter which required special risers. The risers alone took almost two hours as they created thier own headaches related to fitment of the nacelle.

As a side note, the throttle control wires are 43" long, for both the standard or CVO controls. There was no need to extend them to fit these bars. It is not recommended that they be extended on the throttle control unless you record and duplicate the readings of the throttle control so you don't end up with a drivability issue.



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Thank you for an excellent thread with detailed pics....

 

@gree: What an EXCELLENT post. Thanks very much!

 

Thanks for the very informative post. Your customer is very lucky to have a shop that is willing to do custom work like this and figure things out! Where's your shop anyway?
Jerry

 

Nice work, thanks for the pics. HOw does the 'throttle by wire' actually work? Does it use a resistance pot to change voltage and increase or decrease fuel & air based on throttle position?

 

That is some sweet looking stuff. I was a tech for 3.5 years, and our dealership would never have done something like this. Primarily as we did not have the equipment.

That weld job was very impressive. Nice work.

 

Great Post Springer...thanks taking the time to share. That's just an incredible amount of TLC to swap bars for the guy. Good Job. Love the technical information that can be found here.

 

That's pretty much what the dealer did to mine, except he didn't have to lengthen bars, as the pull back was really long. The Flanders handlebar site has instructions on how to make the modification to 1" bars.. Here you go...

http://www.sideroadcycles.com/AmericanMotorcycles/Handlebars/Stock_Bars.html

You'll need to go to the bottom of the page to see the electronic throttle installation.

 

I have a 2009 road glide,looking to go to beach bars.Do you know what extra cables I might need?

 

great post, but I would REALLY think about
replacing my bars before attempting that.
sure would hate to pay a shop to do it
with that many hours involved......
another reason to doubt the wisdom of the
TbyW set up. any shadetree mechanic
could replace bars on the cabled bikes.....

 

No need to do all that anymore for the most part. Lots of bars out now that have that notch built in now. I got the Heritage style put on my '08 Road King Classic. 1.25 hrs of labour, no need for new cables. HD bars have the notch built in.

jober's right. Original h-bar swap in post was done before anyone was making the new bars. Many handlebars are available for the throttle by wire now.




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No need to do all that anymore for the most part. Lots of bars out now that have that notch built in now. I got the Heritage style put on my '08 Road King Classic. 1.25 hrs of labour, no need for new cables. HD bars have the notch built in.