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Wiring Frustrations - Ape Hangers

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Old Apr 16, 2009 | 07:13 PM
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Default Wiring Frustrations - Ape Hangers

I just had new custom 16" ape hangers made from my '09 Street Bob. The bars are not curved and have sharp angles (like z bars). I am trying to do the installation myself to save money.

I have taken apart the wiring terminal connectors and began to attempt to run the wires internally. Due to the sharp turns it is difficult to run the wires. I have tried using string to pull the wires. Now I bent and broke one of the terminal ends. This is starting to get very frustrating.

I am now think of cutting the wires and re-soldering the ends and using heat shrink to protect the soldering. I would just like to hear some suggestions or if this would be the best direction to finishing the wiring. What can I do about the one wire that broke?

Also, I will be relocating my turn signals as I felt that this would help reduce the number of wires I have to run.

Your suggestions and guidance would be much appreciated.
 
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Old Apr 16, 2009 | 07:17 PM
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I'm going to be trying my z-bar install this weekend, going to use k-y for lube, works for other things, hopefully will work for this
 
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Old Apr 16, 2009 | 07:21 PM
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Make sure the holes have no sharp edges.
LOTS of lube.
Push-pull, easy on the pulls.

Save the beverages for after it's done!
 
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Old Apr 16, 2009 | 07:26 PM
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Only thing I can add to shcwangser is that I read elsewhere on this forum that for those zbars a guy ran them thru one wire at a time.

I would avoid cutting and soldering if you can help it.
 
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Old Apr 16, 2009 | 07:26 PM
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cut and solder, the one you broke get a new pin, or pins from the stealer.

were you putting in extensions?
 
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Old Apr 16, 2009 | 07:27 PM
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dishwashing soap will make the job much easier, only down side is you'll find it hard to get a grip
 
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Old Apr 16, 2009 | 08:12 PM
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There are definitely sharp edges that I am concerned about. The sting would get caught as I sucked it through the bars. Because of that, I will definitely be using the black braided line to protect the wires. That complicates matters more since it would make it difficult to run each wire one at a time. I also don't know if lube will on the black line would help.

I am not using an extension kit. The stock wires are long enough.
 
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Old Apr 16, 2009 | 09:04 PM
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if you cut and solder make sure you label the wires appropriately. I don't know what "black braided line" you are talking about but if it fits over the wiring good luck trying to feed it through your bars.
 
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Old Apr 16, 2009 | 11:23 PM
  #9  
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I made sure to take pics before I disassembled the terminal connectors.

I have a black braided plastic sheath that protects the wiring. I don't know if that is a feature new to 09+ models. I don't want got run the wires without it so I can be assured none of the wires will get cut of damaged.

I didn't know that the stealer could sell me the pins. Could I also buy the connector pins at a Radioshack?
 
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Old Apr 16, 2009 | 11:30 PM
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just finished up use lube

also the plastic sheath the wires come in stays on splice afterward
 
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