Dyna Glide Models Super Glide, Super Glide Sport, Super Glide Custom, Dyna Glide Convertible, Super Glide T-Sport, Dyna Glide Police, Dyna Switchback, Low Rider, Street Bob, Fat Bob and Wide Glide.
Sponsored by:
Sponsored by:

Hiding Wires in Handlebars

Thread Tools
 
Search this Thread
 
Old Dec 27, 2009 | 11:50 AM
  #1  
Dyna2007's Avatar
Dyna2007
Thread Starter
|
Intermediate
Joined: Dec 2009
Posts: 27
Likes: 0
Default Hiding Wires in Handlebars

Saw this in another online forum.
Seems a lot simpler and easier, any opinions???

I have run wiring inside handlebars on several bikes and although hd_rider has wrote a thorough description etc. my way is much faster, cheaper and works every bit as well.
If you have basic wiring skills such as sodering and using heat shrink tubing then you can accomplish this in a couple hours without removing your tank or wiring harness. Locate the wiring bundle attached to your handlebars...you will have one comming from each switch housing. remove to black vinyl tube they are routed through. Cut each wire in two making sure you stagger the cuts on each wire bundle. I would advise you to buy new handle bars that are designed for internal wiring. First of all your stock bars have holes drilled in them for the clips that hold your stock wire bundles...you would also have to drill holes in your old bars big enough to run the wiring through, and if you don't deburr it you are liable to short out some wires.
Once you cut the wires in half making sure you stagger each cut on both bundles...strip the ends coming from your controls, now cut some 18 gauge strips of wire...you must determine how long the wiring needs to be especially if your new bars are apes etc..just make sure that the piece you are splicing in is plenty long enough to go all the way out the bottom of your bars and will allow you room to solder it into the wires you cut in two..anyway twist the wires together making sure you slid on some heat shrink tubing....slide it back while you solder...solder the wires...slide the heat shrink over the splice....heat the heat shrink...go to the next wire and so on. I used the same color of wire for all my splices...it doesn't matter cause the color coded wire will be on both ends of the splice. Repeat these steps to connect the other end of the splices.
This is the inexpensive and easy way to do it and I have done it many times with no electrical problems what so ever.
 
Reply
Old Dec 27, 2009 | 04:20 PM
  #2  
08fxdf43202's Avatar
08fxdf43202
Road Warrior
15 Year Member
Photogenic
Joined: Apr 2008
Posts: 1,998
Likes: 14
From: Central Ohio
Default

Originally Posted by Dyna2007
Saw this in another online forum.
Seems a lot simpler and easier, any opinions???

I have run wiring inside handlebars on several bikes and although hd_rider has wrote a thorough description etc. my way is much faster, cheaper and works every bit as well.
If you have basic wiring skills such as sodering and using heat shrink tubing then you can accomplish this in a couple hours ..anyway twist the wires together making sure you slid on some heat shrink tubing....slide it back while you solder...solder the wires...slide the heat shrink over the splice....heat the heat shrink...go to the next wire and so on. I used the same color of wire for all my splices...it doesn't matter cause the color coded wire will be on both ends of the splice. Repeat these steps to connect the other end of the splices.
This is the inexpensive and easy way to do it and I have done it many times with no electrical problems what so ever.
In my opinion.... this is NOT easier and NOT less expensive.
If you have 'basic wiring skills' you should be able to dis-assemble the harness plugspull the wires through the bars & re-assemble the plugs.
Some times the wires don't need lenghtened. But when they do... cutting the wire 1 time, soldering on a length & crimping on a new pin IS easier & less expensive.
 

Last edited by 08fxdf43202; Dec 27, 2009 at 05:10 PM.
Reply
Old Dec 27, 2009 | 04:35 PM
  #3  
FXD2003Rider's Avatar
FXD2003Rider
Administrator Emeritus
Veteran: Army
15 Year Member
Liked
Community Favorite
Joined: Feb 2007
Posts: 9,206
Likes: 970
From: Harmelen (The Netherlands, Europe)
Riders Club Member
Default

Originally Posted by 08fxdf43202
In my opinion.... this is NOT easier and NOT less expensive...
+1......apparently the other online forum doesn't have guys like mud who makes write ups on **HOW TO** (LOL) .............

FXD2003Rider
 
Reply
Old Dec 27, 2009 | 07:03 PM
  #4  
jss1975snow's Avatar
jss1975snow
Cruiser
Joined: Jul 2009
Posts: 235
Likes: 1
From: Delaware/Colorado
Default

Sounds more difficult than an easy wire extension kit. I wouldn't do it. How cheap will you go?
 

Last edited by jss1975snow; Dec 27, 2009 at 07:44 PM.
Reply
Old Dec 27, 2009 | 07:20 PM
  #5  
Hickey's Avatar
Hickey
Road Captain
Joined: Apr 2008
Posts: 577
Likes: 2
From: Brampton, Ontario, Canada
Default

I'll stick with my wire extension kit, haha
 
Reply
Old Dec 27, 2009 | 07:34 PM
  #6  
'09fxdb's Avatar
'09fxdb
Tourer
Joined: Mar 2009
Posts: 493
Likes: 0
From: Newfoundland, Canada
Default

Originally Posted by Dyna2007
Saw this in another online forum.
Seems a lot simpler and easier, any opinions???

Locate the wiring bundle attached to your handlebars...you will have one comming from each switch housing. remove to black vinyl tube they are routed through. Cut each wire in two making sure you stagger the cuts on each wire bundle.
strip the ends coming from your controls, now cut some 18 gauge strips of wire...you must determine how long the wiring needs to be just make sure that the piece you are splicing in is plenty long enough to go all the way out the bottom of your bars and will allow you room to solder it into the wires you cut in two...twist the wires together making sure you slid on some heat shrink tubing...solder the wires...slide the heat shrink over the splice....heat the heat shrink...use the same color of wire for all my splices..the color coded wire will be on both ends of the splice. Repeat
Now with all the extra wording removed...it's pretty easy..+1
 
Reply
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
medicmouse
Electrical/Lighting/Alarm
1
Aug 2, 2017 09:46 AM
DavidB99
Touring Models
1
Apr 13, 2017 07:51 AM
TylerBoehm
Dyna Glide Models
4
Jun 11, 2014 02:14 AM
jmaxx24
Dyna Glide Models
32
Dec 8, 2012 05:55 PM
rubiconMike
Softail Models
19
Aug 29, 2008 07:44 PM




All times are GMT -5. The time now is 04:16 PM.

story-0
7 Times Harley-Davidson Chucked Tradition Out the Window

Slideshow: Harley-Davidson built its reputation on nostalgia, but every so often, the company took a hard left turn into the future.

By Verdad Gallardo | 2026-05-20 11:18:19


VIEW MORE
story-1
7 Surprising Harley-Davidson Products that Are Not Motorcycles

Slideshow: The bar-and-shield logo shows up on far more than motorcycles, some of the company's most unexpected products have nothing to do with riding.

By Verdad Gallardo | 2026-04-29 16:50:35


VIEW MORE
story-2
8 Best Harley-Davidson Motorcycles Ever

Slideshow: Not every Harley gets it right, but these are the ones that genuinely earned their reputation.

By Pouria Savadkouei | 2026-04-15 14:23:21


VIEW MORE
story-3
10 Worst Harley-Davidson Motorcycles Ever

Slideshow: From the troubled AMF years to modern misfires, these bikes earned reputations for reliability issues, questionable engineering, or disappointing performance.

By Pouria Savadkouei | 2026-04-01 20:01:09


VIEW MORE
story-4
Killer Custom's Jail Break Is The Breakout That Refused to Blend In

Slideshow: Killer Custom's "Jail Breaker" build focuses more on stance and visual aggression than mechanical overhaul.

By Verdad Gallardo | 2026-03-18 19:20:32


VIEW MORE
story-5
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?

Slideshow: The Swiss custom shop has taken a Harley Softail and stretched it into something so long and low that it looks closer to a rolling sculpture than a conventional motorcycle.

By Verdad Gallardo | 2026-03-07 16:15:30


VIEW MORE
story-6
Harley-Davidson Reveals Super Cool Cafe Racer Concept

Slideshow: Harley-Davidson's new RMCR concept revives the café racer formula with modern hardware-and it may be exactly the reset the company needs.

By Verdad Gallardo | 2026-03-04 12:23:37


VIEW MORE
story-7
Engraved Rebellion: Inside Bundnerbike's Glam Rock II

Slideshow: A standard cruiser becomes an intricate metal canvas in the hands of a Swiss custom house known for pushing Harley-Davidson platforms far beyond their factory brief.

By Verdad Gallardo | 2026-02-24 18:19:44


VIEW MORE
story-8
10 Motorcycles You Should Never Buy

Slideshow: There is no shortage of great motorcycles to buy, but we would avoid these ten.

By Joe Kucinski | 2026-02-19 14:50:51


VIEW MORE
story-9
10 Things Harley-Davidson Needs to Fix in 2026

Slideshow: Harley-Davidson's challenges aren't abstract; they show up in dropping shipments, shrinking dealer traffic, and strategic decisions that aren't yet translating into growth.

By Verdad Gallardo | 2026-01-13 18:33:17


VIEW MORE