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
Thanks pcross. I'm doing mine soon and your tips will help. Did you entirely remove the handlebar during this process or did you just remove it from the clamps to put the new clamps in place? I'm thinking drill press for the ends, or maybe even chopping an inch or so off the end of the bars depending on how much room I have for controls.
I realize i never responded to this - apologies. You do not need to remove the handlebards, grips or any controls. Just unbolt the top clamp, unbolt the lower clamp from the triple clamp (top socket, bottom box wrench) and leave the bars hanging. Bolt on new lowes (hex top, box bottom), and uppers. I wouldnt mess with a drill press - just have another person help you sight a handheld drill for up/down and front/back and hold the bars solid. Good luck
How bright are the rear turn signals and how visible are they at an angle? Most LED are very bright head on, but not so much at an angle. Thanks
I have hooked up the fronts (embedded in the hand guards) and they seem plenty bright. The rears are very low profile and I haven't yet figured out the best place to mount. Recently installed the PU rear light - turns out that if I install on the stock alum bracket they won't protrude far enough to the sides to be seen from behind. I think I'll end up mounting direct to the sides of the white plastic rear fender. Or they could go on the edge of the license plate bracket (moved over from stock tail light) but that won't look nearly as slick. So I'll report back on results. Appreciate any one else's results on mounting.
I went to install mine this past weekend and wish I would have come back to this thread before doing so. I removed everything because I was going to put the bars in a vice since I don't have a helper handy to hold them steady for me. Turns out the hex head that goes through the lowers was about an inch too short. There was no way it was going to work. So the old stuff went back on and I went riding without the guards. And wouldn't you know it, I dumped it hard (OTB) and broke the clutch lever. So far I've had two falls that have resulted in a broken rear turn signal and a broken lever. Needless to say, I'm looking forward to getting mine all mounted up.
