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Last year I bought my 2010 FXDWG. It's a great runner and I've had no problems with the bike itself. It came with a set of 10" Carlini Evil Apes. Since I prefer standard bars, I found a stock set of Dyna FXDWG bars on eBay and swapped them in. I had no problem installing the new bars but when I tried to remove the internal wires from the Carlinis, the wires themselves slid out of the heavy black plastic casings that the PO had used. That left the casings locked inside of the apes with no apparent way to remove them. Note in the picture attached that there are right angles in four places on the bars. That seems to be the problem.
I had wanted to sell these bars but I can't do that with the casings inside because the new owner wouldn't be able to get his wires in with the old cable housings in place.
So my question is: Does anyone have any ideas as to how I could remove these casings? They are on both sides of the bars. I'd sure like to clean these out so that someone else could use them but otherwise they will go in the scrap metal bin. I've tried to fish them out with needle-nosed pliers but no cigar.
I also phoned Carlini but they don't take calls. They request an email. Thanks in advance for any advice.
.... the wires themselves slid out of the heavy black plastic casings that the PO had used....
So my question is: Does anyone have any ideas as to how I could remove these casings?....
The "PO" you say added these casings, are you talking about something different than the connectors from the wires that plug into the connectors that come out of the steering neck? Those would be OEM connectors?
You say they slid themselves out, would it be more accurate to say that while pulling you pulled them out of the connector, just trying to get the picture here.
Compressed air from the opposite end may help if you can get a seal or, you take a coat hanger and get them dang things out, show 'em who's boss, don't take no for an answer, show 'em really who #2 works for!
Unless I'm wrong about what it is you're talking about, post some more pics
Hi, thanks for the response.
I unpinned the connectors and pulled the wires out of the bars. The tight corners have grabbed the casings and prevented them from coming out of the handlebars. You can look inside the bars and see the ends of the casings but they are too far in to reach. There are apparently some sharp edges in the corners that have locked the casings in.
I'd sure like to show 'em who's the boss but they aren't listening.
I would think leaving the casings in would ease pulling the next set of wires ?
The casings are wrinkled up so that there is no room for new wires to pass through. Also, the two 90 degree angles on each side make it difficult to pass wires even when the bars are empty.
If I had a new set of bars and wanted to install new wires, I would dispense with the plastic casing and just rely on the wire insulation as is. I've seen some installations on Youtube that did it that way and it made the installation very easy.
I'm still working on the bike to finish installing the new standard handlebars but when time permits, I'll give another try to clear the Carlini bars. Failing that, they go to scrap.
Bend a small hook on the end of a piece of bale wire. Run the straight end of the bale wire through the end of the bar, let's say the throttle end. Figure out a way to loosely plug/cover the 2 holes at the end of the bar, I'm thinking of something like a piece of saran wrap.
You don't want to plug off the end of the bar, just restrict the flow.
Boil a couple gallons of water on the stove.
Start pouring the water in the center hole on the bars and allow it to dribble (restricted) out the end of the bar so that it heats up and softens the wire sheath that is stuck in the bars.
Start pulling on the bale wire that's laced thru the center hole of the bars.
It's either going to snag on and pull out the now softened and flexable sheath or it's also going to get stuck in there too and then you're royally f***ked.
Good luck and have fun.
Oh, and take pictures.
Ż\_(ツ)_/Ż
Last edited by Uncle 'B'; Sep 21, 2023 at 11:56 AM.
What about using long needle nose pliers grab hold of the end start twisting and pulling out.
I tried that on one side this morning just for fun and managed to remove a short section of the covering. That stuff is rather hard. (See picture), That left another piece in a blind section of the bars where it's completely inaccessible. LOL
I've determined that I will likely bore a 1/2" hole at the apex of each 90 degree angle. That will expose the remainder of the tubing. Bear in mind that there are also three other holes in the bars: One in the center where the wires come out and one one each side where the wires enter the control switch pods.
I'll drill a 1/4" pilot holes on my milling machine and then finish the holes with a 1/2" Ball mill so that the holes are very clean. Then I can reach the remainder of the casing material with a wire hook. The holes will be plugged with rubber plugs that I already have in stock. Necessity is the Mother of invention.
Last edited by FX WideGlide; Sep 21, 2023 at 01:04 PM.
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Problem with Carlini Evil Apes.
