internal wiring for stock handlebars
Cruiser
Joined: Jul 2007
Posts: 188
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RE: internal wiring for stock handlebars
I just finished mine a few days ago. I drilled a ½” hole under each housing and a ½” slot under the clamps. Cleaned it up a bit with a die grinder, taped them off and spray painted the bare metal. I have the black Harley mini-apes. Minus the turn signal wire, I was able to push the rest, still in the stock black weaved shield through the bars without any chase wires. They just slid through and I had to use needle nose to get a hold of them through the bottom but then they just slid on through. Didn’t solder either. Just pulled the pins out of the connectors and once you remove the plastic shield under the tank, there is plenty of slack to pull the connectors out and work with them. Just remember, if you pull the pins from the connectors, make notes of where they go.
Road Master
Joined: May 2006
Posts: 874
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RE: internal wiring for stock handlebars
I am a master electrician and internal wiring is a piece of cake. I drilled out stock black HD mini apes with no problems. I used a step bit on an angle to drill the holes under the controls and
drill 2 3/8" holes and connected them with a dremmel equiped with a cut off wheel at the bottom of the bars. Just be sure to file all the burrs from the holes. I used the dremmel for this also.
I put my bars in a shop vise with wood blocks to protect the bars.I taped off the bars with a little painters tape andsprayed the holes with a little black rattle can. Before your put the bars on
take some mason line or similiar pull line and a couple fishing split shots and just shake thedrag line through the bars. Its just that simple.Your can make a drawing of the wire connectors but
its not needed. The right and left are color coded, 1 is white and 1 is grey. When you put them back together just match the male side colors to female side colors.
Be careful not to bend the duetsch connector ends. I pulled my tank because it just makes the job easier. I would also suggest when you pull the brake side controls tie a string to the master cylinder and hand it from your ceiling. If you just let it hang like the other side it will leak a little. I taped the wire bundles with high grade electrical tape before pulling it into the bars.
Then I trimmed the black mesh wire sleeve and shoved a good 2" into the bottom of the bars and tye wrapped the sleeve just under the bars with small black tye wraps and then tye wrapped
the 2 wire bundles together for a nice clean look. If you're doing the bars you may want to replace the rubber riser bushings with the poly bushings depending on what model you own.
Good luck. PM me if you have any questions.
drill 2 3/8" holes and connected them with a dremmel equiped with a cut off wheel at the bottom of the bars. Just be sure to file all the burrs from the holes. I used the dremmel for this also.
I put my bars in a shop vise with wood blocks to protect the bars.I taped off the bars with a little painters tape andsprayed the holes with a little black rattle can. Before your put the bars on
take some mason line or similiar pull line and a couple fishing split shots and just shake thedrag line through the bars. Its just that simple.Your can make a drawing of the wire connectors but
its not needed. The right and left are color coded, 1 is white and 1 is grey. When you put them back together just match the male side colors to female side colors.
Be careful not to bend the duetsch connector ends. I pulled my tank because it just makes the job easier. I would also suggest when you pull the brake side controls tie a string to the master cylinder and hand it from your ceiling. If you just let it hang like the other side it will leak a little. I taped the wire bundles with high grade electrical tape before pulling it into the bars.
Then I trimmed the black mesh wire sleeve and shoved a good 2" into the bottom of the bars and tye wrapped the sleeve just under the bars with small black tye wraps and then tye wrapped
the 2 wire bundles together for a nice clean look. If you're doing the bars you may want to replace the rubber riser bushings with the poly bushings depending on what model you own.
Good luck. PM me if you have any questions.
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ZeroFiveFour
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