Mounting chrome handlebar controls on Harley-Davidson

We like to customize our motorcycles, it's a fact. Customization usually involves modifying or replacing standard components, but the truth is that custom model manufacturers are making it increasingly difficult for us, as the trend in recent years is to release factory-customized models. I'm not referring to extravagant showbikes, but rather to a strong desire on the part of brands to "copy" the essence of the street and bring it to their production models.
This, which in principle is an advantage, requires more effort when making changes to our frame, since they come almost perfect and finished, with hardly anything missing or extra.
However, in today's article, we'll get ahead of the aesthetic trends. While it's true that fashion is cyclical, after moving away from the chopped, black bobbers and boardtrackers, we'll surely now experience a revival of the '70s and '80s with flake paints, choppers, and chrome! If you don't believe it, check out HD's latest Hard Candy paints, or its Seventy Two model.

Chrome plating the controls
In this case we are going to add a little chrome to the handlebar of a Sportster model by completely changing the handlebar controls , grips and buttons .

We could have installed chrome covers, but I don't recommend doing this on a custom bike, as it would break its minimalism and the bike would end up becoming a "shiny junkyard" car. It's better to replace functional parts with aesthetically improved ones. In this case, the chrome will protect the parts better than the original paint against brake fluid corrosion, insect impacts, and inclement weather.

Performing the installation
We'll start with the throttle cables. After loosening them and opening the control unit, we'll remove the brass terminals, which will allow us to uninstall the cables from their housing.

With the cables out we can now remove the supports for the electric buttons,

It is very important to take a photo or consult the manual to reinstall it later exactly as it was, otherwise the cables can get caught between the housing and the handlebar.

We will also disconnect the brake pump and the clutch (be careful with the brake fluid, it stains all the surfaces it touches), and we will remove the left handlebar grip (sometimes it is glued and has to be cut).
The final step is to remove the button housings by prying them off with a small screwdriver.

Kit assembly
We'll begin installing the kit by replacing the buttons, applying light pressure until they click into place.

We continue with the assembly of the switch housings, throttle and clutch cables, and brake hoses. We'll do all of this following the procedures and tightening torques recommended in the owner's manual:
-Clutch and brake clamp screw...12.5 Nm

-Switch housing screw...2.5 Nm
-Brake hose banjo bolt...25 Nm
After completing these steps, the work is practically complete.

Now all that remains is to add brake fluid ( Dot 4 or 5 , depending on the year and model) and bleed the air from the hose, for which we can use a brake bleeder .

Final checks
We must check the operation of all switches, including the brake light. The brake lever must be applied firmly and smoothly, and the levers should be aligned in a natural position for the wrists.
Once these checks are complete, we'll thoroughly clean the entire assembly with alcohol or a mild degreaser and then go for a test ride to check the buttons, brakes, etc. while driving.

Frank Burguera

#harleymechanics