Thanks for the reply,

The plug with the black and white wires is on the brake side. I suspect it is the one that goes to the TBW control that the right grip goes to. I figure I'll drop by the dealer today and pick up a set and see what they look like.

Do you recall what you did to pull the wires from the left grip through? I was thinking of using a stiff wire as a fish tape. I just don't know if it would be best to go out from the center of the bars or go down and try to fish it out of the hole somehow.

 

If I remember, there is only one connection to the bike. One of the leads from the TGS should match the red/black that you finally found (you may need one of the jumper wires included)...this is what powers the right/throttle grip. Then the another lead from the TGS goes to the connector you've pulled through the bars on the left side and powers it (once the little plug in the end of the TGS is installed). I think...if I'm not mis-remembering??

Because my bars are internally wired with all wiring, the left side was a b*tch getting all the wires through. Plus I used a dremel and enlarged the hole at the bottom of the bars to make room for everything. I used weed wacker/trimmer line and fed it through from the grip end. You have to pull the wires from the grip end down to the bottom center.

 

Never mind...disregard my previous post as I think I had it backwards...I think?!?! Power from the red/black plug you found goes to the left grip (with heat control switch on it). Then there is a second lead from the left side that plugs into the lead coming from the TGS. Once the little plug is installed in the end...power to the throttle side. Man this aging thing is hard on the memory banks.

 

Right grip has the TGS Sensor, and will have the black/white wires (#1 in your diagram) already in the fairing, it plugs into the black/white wires coming from the left grip. The other wire(s) coming from the left grip, are the red/black wires, these are you power wires that plug in the the red/black wires under your fairing (#3 in your diagram). I used a stiff piece of safety wire as a wire-fish... slid it down from the left bar end to the hole in the middle, just try to get it under or over the switch pack wires (not thru them) to make pulling the wires easier. It should not be difficult though. Once you see your fish-wire showing in the center of the hole at the center of the bars, I take a tie wrap and push it in at the top of the cut-out of the center hole and let it curl around and out on the bottom of it, thereby circling the fish-wire, making it easier to pull it out... if you can't get a hold of it easy with a pair of needle-nose. Also, on the 2010 we did last month, I did not have to use any of the extensions to make the two connections... At first I thought I needed the short one for the power wires (R/B), and with those hooked up the grips wouldn't heat up at all. I took the short extension off, plugged it back together without it and the grips heated up fine. So, I got out a continuity tester and the damn extension had a bad crimp on one of the wires, brand new out of the box... To me the toughest thing always, is getting the little plug lined up and seated in TGS sensor under the right grip's end-cap... but its probably a patience thing lol

 

Here are the instructions for the Harley grips. Pretty straight forward install. Hardest part for me was fishing the wires thru the bars. I had a fish tape from a Heat Demons install that I did on a different bike which worked pretty well.

 

Looks like the kit that the dealer had must have been old stock. The left grip has one wire going inside the handlebar and one going outside of it. The instructions are dated 2017-01-16. Here is a picture of it:



Also none of the plugs match up. The power wire from the left grip is stupid long and has an inline fuse in it. It will have to go outside the bar. The control wire that feeds the right grip has a female plug connector on it, just like the one in the harness does, so they will have to be spliced somehow.

I hope there is enough room for the power wires to feed out of the left control housing. This is going to be fun. Leave it to Harley to have forty eleven different versions of the same part number product.

Also I forgot to mention. Where there is just one two wire plug on the newer version of the grips on the left for power there are three wires. An orange with a white stripe, a black one, and a red wire with an inline fuse. I wonder why there are three power wires instead of two?

 

^^ This...exactly what Ssitruc said ^^

 

I'd be tempted to return those...doesn't sound like the right application. Certain ones are for all internal wiring, some aren't.

 

I did some googling and found that this is the way the off the shelf "multi fit" grips are sometimes manufactured. The power wire on this version is intended to go outside the handlebar. The wire is intended to drop down between the grip and the switch housing.

I have found three different service bulletins from Harley on this same part number, so I am guessing there have been three different revisions of this same part. I could return them and ask the dealer to order another set, but all they can do is order the same part number again. There is a chance I would wind up with the same design again. I already had the bike apart and didn't feel like putting it back together again temporarily so I went ahead and used these. I had to remind myself that I earn my living making things work that other folks don't want to fool with.

I found this in an older post when someone asked about the three wire version:

Since the plug on the brake side in the fairing had the connector on it that mated to the power plug on the wiring harness on the clutch side I cut it off and used it as a connector for the power wires coming from the left grip. That turned this:


Into this:


I then plugged it into the power plug in the harness that was made for the grips and used insulated quick disconnects to connect the crossover wire to the right grip. I figure that way when I work on the inner fairing they can both be unplugged and moved out of the way if necessary. Since my bike still has the factory external wiring it don't bother me that the left grip power wire is external. I just used small black wire ties to secure it to the harness that was already there from the left control housing.

The funny thing is running the wire through the handlebar was the easiest part of the job. I just pushed a straightened coat hanger I use for fishing wire UP from the center of the bars out the left handlebar. I then tied a piece of 14 gauge THHN wire to it and pulled it back through. Next I taped the internal wire for the left grip to that wire and pulled it on through with no trouble at all.

I still have the fairing apart but I've gotten the inner fairing and grips mounted back and the grips heat up fine. They get almost hot at number three with the bike off so I figure they must be doing OK.

Thanks again for everyone's info and help. Looks like all is well after the standard "make it work somehow" method of installing OEM Harley parts.

 

Glad to hear you got it figured out & working for you Hoyt! And yes, they get very toasty. I find that when I arrive home from a ride with the setting on 2-3, when I take my glove off to operate my remote for the garage door, the grip is too hot to grab with bare hands. Now get that thing put back together and go out & ride...because I can't for a couple more months