Heated Grip Installation Guide (Softail Models)

In this guide, we’ll walk through the installation of pre-wired handlebars on a Softail, covering everything from removing your stock bars to wiring up your new controls.

Tools & Accessories You'll Need:

• Pre-wired handlebars (including any provided heat shrink and wiring accessories)
• Screwdrivers
• Wire cutters
• Wire strippers
• Pick tool
• Solder seal connectors
• Heat gun
• Cable lubricant (we recommend Cable Life)

Step 1: Removing the Stock Handlebars & Controls

1. Remove the Stock Controls:
   • Each set of controls is secured with two screws. Fully remove them and set them aside—you’ll need them for reinstallation.
   • Be careful not to lose any screws.
2. Detach the Grips:
   • Cut and remove any zip ties holding the wiring in place.
   • Slide the grips off the handlebars.
3. Disconnect the Stock Heated Grip Connector (if applicable):
   • Use a provided key, a pick tool, or another method to carefully detach the connector.
   • If you don’t have heated grips on your Softail, this step may not apply.
4. Remove the Stock Twist Grip Sensor:
   • Use a pick to lift the small tab inside the sensor, then push from the bottom while gently pulling from the top.
   • Because of the bend in the bars, you’ll need to apply steady pressure while guiding it out.
5. Remove the Control Wiring and Turn Signals:
   • Push the wiring from the bottom of the bars while pulling from the top.
   • Once everything is detached, set aside the stock bars—you won’t need them anymore.

Step 2: Preparing the New Pre-Wired Handlebars

1. Unwrap the new handlebars:
   • Remove any tie wraps securing the wiring.
   • Read through the provided instructions to ensure you're familiar with the installation process.
2. Measure & Trim Wires for Proper Fit:
   • The turn signal wires should extend 8 inches past the controls.
   • The control wires should be trimmed to 5 inches past the controls.
   • This allows for 3 extra inches of turn signal slack once everything is installed.
3. Organize Left & Right Control Wiring:
   • Ensure you keep left-side wires with the left controls and right-side wires with the right controls.
   • Mixing them up will cause issues when reassembling.
4. Expose the Wiring:
   • For control wires, pull the outer casing back about 2 inches and trim any excess.
   • For turn signal wires (since the casing can’t be pulled back), measure and cut 2 inches carefully without damaging the wires underneath.
5. Strip the Wire Ends:
   • Expose about ¼ inch of copper on each wire to prepare for connections.
   • A standard wire stripper (from Home Depot or similar) works best.

Step 3: Connecting the Wiring with Solder Seal Connectors

1. Identify the Turn Signal Wires:
   • Turn signal wires will be marked with white heat shrink tubing for easy identification.
2. Use Solder Seal Connectors:
   • Slide a solder seal connector onto each wire before twisting connections together.
   • The smaller opening of the connector should face the handlebars, while the larger end will cover the twisted wire connections.
3. Twist & Connect the Wires:
   • Start with the black wires and twist them together.
   • Fold the wires neatly and slide the solder seal connector over them, ensuring the solder portion covers the exposed copper.
4. Heat to Seal the Connections:
   • Use a heat gun to melt the solder inside the connector.
   • The heat shrink casing will also seal the connection, protecting it from moisture and vibration.
   • Be careful not to overheat the connector, as it can damage the wiring.
5. Repeat for Each Wire Color:
   • Work through each set of wires, starting with turn signals to get them out of the way.
   • Continue with control wires using the same solder and heat-shrinking method.
6. Final Heat Shrink Protection:
   • Once all wires are connected, slide the provided heat shrink tubing over the entire set of connections.
   • Heat it to create a secure, protective seal.
   • Let everything cool before moving on.

Step 4: Installing the Twist Grip Sensor & Routing Wires

1. Lubricate & Guide the Wiring Through the Handlebars:
   • Use cable lube to make it easier to feed the wires through the bars.
   • Push from the bottom while gently guiding the wires from the top—avoid pulling too hard.
2. Install the Twist Grip Sensor:
   • Apply lubricant to help it slide in smoothly.
   • Guide it carefully into place—this side is typically harder to install.
   • Ensure that it’s fully seated and properly aligned.
3. Complete the Wiring Routing:
   • Make sure all control wires, turn signal wires, and the twist grip sensor are correctly positioned.

Step 5: Reinstalling the Controls

1. Start with the Twist Grip Sensor Side:
   • Since this side is more complex, it’s best to install it first.
   • You’ll be working with five control wires, three turn signal wires, and the twist grip sensor.
2. Repeat the Process for the Clutch Side:
   • Install the clutch-side controls following the same steps.
3. Secure Everything & Prepare for Final Installation:
   • Double-check all wiring connections.
   • Ensure the controls are securely reinstalled using the screws you set aside earlier.

By following these steps, you’ve successfully installed pre-wired handlebars on your Softail. This process is much easier than running all the wiring from scratch, and with the solder-sealed connections, you’ll have a durable and reliable setup.

Now your bars are fully wired and ready to be mounted on your bike.