Handle bar removal on Dream and left side controls

[bbap]

Has anyone had recent experience removing their handlebars from a late Dream 305? I've gotta replace my bars and the left side controls where the wire comes through the bars and attaches to both the horn and high/low beam is holding me fast.

Is it easier to remove the front headlight and bar clamps and push out some slack and disconnect the controls or is their an easier way?

As always, thanks much!

Steve

[Hahnda]

I would start with unhooking the wiring in the headlight shell for the controls. Then remove the bars from the bike. Then remove the controls from the bars. The old wiring is going to be pretty stiff so it probably wont be all that easy to get out.

[brewsky]

I would start with unhooking the wiring in the headlight shell for the controls. Then remove the bars from the bike. Then remove the controls from the bars. The old wiring is going to be pretty stiff so it probably wont be all that easy to get out.

Ditto to that!
The wires are soldered to the contact plates in the switch and don't like to come out toward the bottom of the bars.

You could blow some hot air from a hair dryer or the like in the end of the bars to try and soften up the wires, and shoot some WD40 in there also to try to prevent skinning the insulation when removing.

[bbap]

Thanks Guys, I removed the wiring in the headlamp and used some spray silicone. Came out like a dream...Thx!

[milwaukeephil]

Did you have to do some milling on the new bars or did you find some with the slot?

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I don't have access to a Mill, so I used a dremel and went very, very slow. So far so good. Just waiting on a small part to put her back together. A Mill is the way to go, though.