Just finished the install and thought I'd share a couple observations. There's a lot out there on doing an install so I won't do soup to nuts.
Did this on a 2008 TE 450.
1) Bar ends need to be drilled out from approx 7/16 to 9/16. I used a unibit to make sure centered and stepped up first to 1/2 then 9/16. Of course, the unibit only lets you get in about a 1/4" so then went to a 9/16 drill. Make sure you take a look at your drill bit set as most only go up to 1/2". I ordered a good 9/16 bit on amazon for about $12. You really want someone to hold the bars steady and level and help sight your line. I drilled in about a 1/4" deeper than the threaded insert. I also drilled out the plastic end of the throttle tube, then dremmeled until i could slide the whole unit inboard so it would not interfere with the hand guards.
2) Tap: no issues here but take your time starting it. I backed out, blew out the shavings with compressed air (watch your eyes) and applied WD40 liberally - did that about 3 times. My tap from HDB did not have a line to indicate depth so when i got close i blew out, tried insert, and tapped until the insert seated about 1/16" inside the bar ends.
3) Top/bottom mounts: i ordered 93 x 38/48mm top and lowers. Apparently stock is 93x50 but HDB does not support so you need to order lowers in this size. I ordered the 1 3/4" lowers but this turns out to be lower than stock. The stock spacers will not fit with supplied bolts. Since I want to raise my bars I may buy longer bolts or see if HDB will swap out to taller units.
4) I ordered the top clamps with powerlet and switch options and plan to wire up next weekend - will report back on that.
5) I got a single mirror and attached to left side - as others have said, the mirror is awesome and works perfectly.
6) Turn signals. Bullet connectors were supplied so once you test for polarity just crimp on and hook together and your done. On mine (as i recall), positive on right blinker was red, positive on left blinker was light blue.
7) Flasher: my blinkers blinked fast with stock flasher (note you need to start engine not just key on to get blinkers working). My flasher unit was dangling loose on left side of bike in air box down next to the filter. The flasher supplied by HDB has a connected that did not mate up so clipped ends of the new flasher, the husky wire harness and added bullet connecters and insulaters. Wrapped the whole thing in electrical tape and zip tied next to subframe by battery.
8) I also ordered the rear LED signals but these do not fit in the stock location (they are so low profile that they do not extend beyond the black plastic taillight assembly). As my power up included a new tail light (but its in the mail) i expect I'll mount the signals direct to the new unit.
Results: as many have observed, these things are the bees knees. The mirror and turn signal integration clean up the front end nicely. When out testing, the bike fell of the sidestand (arrgghh) and crashed onto the right side pretty hard - a little knick on the aluminum but they functioned perfectly.
Hope this helps.
Peter
Did this on a 2008 TE 450.
1) Bar ends need to be drilled out from approx 7/16 to 9/16. I used a unibit to make sure centered and stepped up first to 1/2 then 9/16. Of course, the unibit only lets you get in about a 1/4" so then went to a 9/16 drill. Make sure you take a look at your drill bit set as most only go up to 1/2". I ordered a good 9/16 bit on amazon for about $12. You really want someone to hold the bars steady and level and help sight your line. I drilled in about a 1/4" deeper than the threaded insert. I also drilled out the plastic end of the throttle tube, then dremmeled until i could slide the whole unit inboard so it would not interfere with the hand guards.
2) Tap: no issues here but take your time starting it. I backed out, blew out the shavings with compressed air (watch your eyes) and applied WD40 liberally - did that about 3 times. My tap from HDB did not have a line to indicate depth so when i got close i blew out, tried insert, and tapped until the insert seated about 1/16" inside the bar ends.
3) Top/bottom mounts: i ordered 93 x 38/48mm top and lowers. Apparently stock is 93x50 but HDB does not support so you need to order lowers in this size. I ordered the 1 3/4" lowers but this turns out to be lower than stock. The stock spacers will not fit with supplied bolts. Since I want to raise my bars I may buy longer bolts or see if HDB will swap out to taller units.
4) I ordered the top clamps with powerlet and switch options and plan to wire up next weekend - will report back on that.
5) I got a single mirror and attached to left side - as others have said, the mirror is awesome and works perfectly.
6) Turn signals. Bullet connectors were supplied so once you test for polarity just crimp on and hook together and your done. On mine (as i recall), positive on right blinker was red, positive on left blinker was light blue.
7) Flasher: my blinkers blinked fast with stock flasher (note you need to start engine not just key on to get blinkers working). My flasher unit was dangling loose on left side of bike in air box down next to the filter. The flasher supplied by HDB has a connected that did not mate up so clipped ends of the new flasher, the husky wire harness and added bullet connecters and insulaters. Wrapped the whole thing in electrical tape and zip tied next to subframe by battery.
8) I also ordered the rear LED signals but these do not fit in the stock location (they are so low profile that they do not extend beyond the black plastic taillight assembly). As my power up included a new tail light (but its in the mail) i expect I'll mount the signals direct to the new unit.
Results: as many have observed, these things are the bees knees. The mirror and turn signal integration clean up the front end nicely. When out testing, the bike fell of the sidestand (arrgghh) and crashed onto the right side pretty hard - a little knick on the aluminum but they functioned perfectly.
Hope this helps.
Peter
