Zbar wiring
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Road Master
Joined: Jul 2008
Posts: 1,021
Likes: 2
Zbar wiring
Has anyone had any luck internally wiring 1 inch z bars. I got a set from Road6customs. They are pre-drilled. I can't seem to get the wires through. I've tried them bundled and taped and can't get past the first bend. I've tried them one at a time, and can get 3 wires all the way through after that I can't get anymore. If any one has any tips on this I'd greatly appreciate it. If these were normal apes I'd have been done hours ago.
Road Captain
Joined: Aug 2007
Posts: 667
Likes: 1
From: Vancouver Wa.
Do them one at a time, I used a piece of weed eater line as a guide on these. There should be a hole in the bar below the second bend. Fish the guide line through that hole past the first bend and then out the hole at the controls. Pull the wire to the hole then use your / guide again to get it to the hole at the risers. 6 wires / side, should take 2 hours or so.
Thread Starter
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Road Master
Joined: Jul 2008
Posts: 1,021
Likes: 2
Do them one at a time, I used a piece of weed eater line as a guide on these. There should be a hole in the bar below the second bend. Fish the guide line through that hole past the first bend and then out the hole at the controls. Pull the wire to the hole then use your / guide again to get it to the hole at the risers. 6 wires / side, should take 2 hours or so.
I'm already using the weedeater line, that seems to work the best as far as a guid. I only have three holes in the bars. The two at the controls, and the one between the risers. Are you saying yours has another hole at the bottom bend? At least it sounds like I'm on the right track running the wires one at a time. Mine are the 12 inch zbars by the way.
Road Captain
Joined: Aug 2007
Posts: 667
Likes: 1
From: Vancouver Wa.
I'm already using the weedeater line, that seems to work the best as far as a guid. I only have three holes in the bars. The two at the controls, and the one between the risers. Are you saying yours has another hole at the bottom bend? At least it sounds like I'm on the right track running the wires one at a time. Mine are the 12 inch zbars by the way.
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Joined: Jan 2007
Posts: 1,658
Likes: 3
From: NorNev
I got some cheaper Z bars for my Sporty - rough inside welds and no extra access holes to help with wiring. First side I tried a wire ended up grounded to the bars. Searched the forum and picked up hints from hear and there. Then this is a short version of what woked for me. I did not do the individual wire method because i thought the inside welds were too rough and would rub through the wire insulation easily.
I used this stuff for my sporty bars.http://www.lowes.com/lowes/lkn?actio...8-6&lpage=none
- Strip off loose wiring sleeve.
- Replace with one piece shrink wrap (Fryes). Heated tight but bendable.
- Over that one layer of Security packing tape put on lengthwise so fibers go with the wire, cut off excess. This type: http://www.3mselect.co.uk/p-879-scot...dispenser.aspx This stuff is more slippery and another layer of protection.
- I used weedeater line to pull the wire through. Overlap it with the end of harness wires at least 8" and wrap with electrical tape. Do no tie - too big of lump. Make sure all transitions are smooth and bendable.
- Use plenty of lube and push in first and then pull - small patient steps.
I used this stuff for my sporty bars.http://www.lowes.com/lowes/lkn?actio...8-6&lpage=none
- Strip off loose wiring sleeve.
- Replace with one piece shrink wrap (Fryes). Heated tight but bendable.
- Over that one layer of Security packing tape put on lengthwise so fibers go with the wire, cut off excess. This type: http://www.3mselect.co.uk/p-879-scot...dispenser.aspx This stuff is more slippery and another layer of protection.
- I used weedeater line to pull the wire through. Overlap it with the end of harness wires at least 8" and wrap with electrical tape. Do no tie - too big of lump. Make sure all transitions are smooth and bendable.
- Use plenty of lube and push in first and then pull - small patient steps.
Cruiser
Joined: Mar 2008
Posts: 174
Likes: 0
From: Clifton, ME
same thing, slight variation, use a vaccum to suck a piece of string through, followed by either stronger string, or your wires taped to the string really well. if you stagger the wires so that the ends start every half inch or so , kinda like a staircase, you can flex them through a little more easily (if you have enough play in the wires to do so).
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Tourer
Joined: Nov 2008
Posts: 389
Likes: 0
From: Tempe, Arizona
we did mine with some cord attached to pull them through, still wasn't quick and easy though but well worth the time once their finished
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I used the vacuum to suck a sweatshirt string though the bars and pulled three wires at a time. I used electrical tape to hold the wires in group of three and I taped the **** out of um so they wouldn't get stripped on my sharp bends.
as said above, i use high tension fishing line but it is all the same... 1 at a time is what it takes... i blow 1 line though to that i tie fishing line 1 piece for however many lines of wires i need to get though , that way i just tie and tape, i wire per line and pull them out 1 at a time... works great