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Sportster Models 883, 883 Custom, 1200 Custom, 883L, 1200L, 1200S, 1200 Roadster, XR1200, and the Nightster.
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Old 07-15-2010, 09:21 AM
midnight2005 midnight2005 is offline
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Default how to wire HD handlebars

ok so I was on the front page of HD forums and seen this article. I thought, this would be great for the sporty guys! Then I read it.

What a joke! It says nothing about how to get those darn plugs apart that are such a pain in the ars, where to unplug them or how to put them back together! Nothing about removing grips or removing the throttle or anything. I suppose they will say something like," well you should know how to do that"
Here is a news flash, any idiot can pull the wires through the bars! Were not talkin rocket surgery here.










How-to Wire Harley Davidson Handlebars Internally

By HDForums Editors on July 7, 2010 6:32 PM

So, you've decided you would like a new set of handlebars on your Harley-Davidson ride. You've opted for a more radical set that will give you a better feel as you ride and a smarter look. Great. But what about the wires that operate your turn signals and other electronics, which run through the bars? These will have to be installed along with the new handlebars. Fortunately, installing the wires internally is a relatively simple process, which you can do yourself. If you plan to install your new handlebars yourself, you can also install the wiring harness yourself. The process is that simple.

Items You Will Need
You will require three items to complete this job:
  • masking tape
  • a pull chain
  • the wiring harness
Preparation
Before installing the wires into your handlebars, you will have to make some initial preparations.
  1. Pick a large wire on the harness that will serve as your "main" wire. You are going to be attaching the other wires to this wire before you pull the harness through the bars.
  2. One by one, use masking tape to attach the other wires to the main wire. Do this in a staggered pattern. In other words, first attach a wire an inch or so below the end on your main wire. Attach the next wire an inch or so below the second wire, and so on. In order to run all of the wires through the handlebars, you will probably have to make at least two "sets" of these wire bundles, each having two or three wires in the staggered pattern previously mentioned. Staggering the wires prevents there being a large "ball" of wires, which would have a difficult time passing through the handlebars easily and especially getting around abrupt corners.
Process
  1. If you have not done so already, run your pull chain (no wires attached) through the handlebars by inserting it into the end of the handlebars and out the end of the bars.
  2. Now that you have your wires all setup, you will want to secure them to the end of the pull chain, which is protruding from the handlebar end. Do this in a staggered pattern also; in other words, attach one wire bundle on the end of the chain, then a couple of inches down from this bundle, attach the next bundle to the chain.
  3. Next, in a "push-pull" motion, pull the chain at the bottom of the handlebars with one hand; at the same time push the bundles of wires through the handlebars with your other hand. Push and pull the wires attached to the pull chain as many times as it takes until the wires come out the end of the handlebar.
  4. Do the preparation, and pulling through of the wires, for both sides of the handlebars.
  5. Now your wires are through the handlebar and you are done. You can remove the pull chain and begin to install your new handlebars.
After your new handlebars are installed and you have re-installed all of the instrumentation, you have a new look and feel to your Harley-Davidson motorcycle. Ride on!
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Old 07-15-2010, 09:25 AM
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xFreebirdx xFreebirdx is offline
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The Service manual has the missing information IE; pin removal and pin location. You'd have to have the manual when you do it cause you will need to put the wire pins back in the correct spot.
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800 Open Mod 268hp (Rotax)
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1996 D3500 V10 425hp 600+lbs tq.
1996 HD 1250 XLH "Custom" Stage 2 Heads, SE.497 Cams, SE Prog. Race Ignition.
A Tiger Doesn't Lose Sleep Over the Opinion of Sheep.
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Old 07-15-2010, 09:35 AM
midnight2005 midnight2005 is offline
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so if we have the manual, why do we need these instructions? once again any idiot can pull wires through the bars, If they are smart enough to figure out the manual and plugs, then they can figure out how to pull some wires
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Old 07-15-2010, 10:20 AM
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xFreebirdx xFreebirdx is offline
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Well maybe they need to post the instructions for choosing motor oil too. Do a search on internal wiring and you'll have your answer. Its amazing how many people have asked how to get the wires though the bars. . Its hard to understand why idiots do the things they do. lol
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800 Open Mod 268hp (Rotax)
617 Mach1 on NOS (Rotax)
1996 D3500 V10 425hp 600+lbs tq.
1996 HD 1250 XLH "Custom" Stage 2 Heads, SE.497 Cams, SE Prog. Race Ignition.
A Tiger Doesn't Lose Sleep Over the Opinion of Sheep.
Vet: ★US ARMY 78 - 81★Patriot Guard Rider ID#45266 07/06/06★
1996 HD 1250 XLH
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Old 07-15-2010, 10:20 AM
 
 
 
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2008, bars, davidson, handle, handlebar, handlebars, harley, hd, pin, plug, pull, run, sportster, threading, wire, wires, wiring


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