Help with wiring

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Feb 22, 2010 | 07:27 AM

grizzwold

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Joined: Sep 2008

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From: Jersey Shore

Help with wiring

Just finished swapping the handlebars on my Street Bob and the only issue I'm having is trying to get all the wiring back in the neck gusset. I was able to kinda jam it all in there and get the rubber grommets back on, but I don't remember it being that tight when I pulled them out. I'm a little worried that there is too much stress on the wires and connectors. Anyone else run into the same thing? Am I worrying for nothing?

Grizzwold

Feb 22, 2010 | 07:32 AM

J-RoX

Cruiser

Joined: Jun 2009

Posts: 143

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From: upstate NY

mine are all very tight as well... i am unhappy about it, but i actually had to cut my left side grommet.

Feb 22, 2010 | 07:39 AM

rounder

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Joined: Oct 2007

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From: Palm Harbor fl.

in the gusset out the back of the frame backbone... a little tug on the wiring harness from under the seat should help out quite a bit in getting the wires back into the frame. I always have to push /pull them through.

Feb 22, 2010 | 07:46 AM

jmpancoast

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Joined: Jan 2007

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From: Chesterfield, VA

I have run internal wiring through my bars, added digital speedo/tach, relocated signals, relocated ignition switch, and a couple other things which relate to wiring coming out of the neck. My wiring was so tight I could hardly get the grommet back in. It also restricted movement of the harnesses making them pull tight at full turns of the front end.

I relied on a thread created a couple years ago by"WS6 Formula". He completely re-did his wiring to clean-up the neck area and it looked great. I went back in the neck a couple times, cleaned up the harnesses, and finished it up with good results.

I recommend searching for his thread and seeing if something similar can benefit your situation.

Feb 22, 2010 | 07:53 AM

8541hog

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Joined: May 2008

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From: Ogden, UT

Over time stress on wires is not a good thing, it will eventually lead to failure. I agree with jmpancoast, take care of it now so you don't find yourself stranded somewhere.

Feb 22, 2010 | 07:54 AM

grizzwold

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From: Jersey Shore

thanks guys, i just wanted to make sure I wasn't the only one having this same issue.
I'll look for that thread JMP. It's definitely something I may consider doing now especially with riding season still being a couple weeks away.

Feb 22, 2010 | 08:26 AM

SC-Longhair

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Joined: Feb 2008

Posts: 11,483

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From: Passaic County, NJ

Did you leave enough slack from the neck to allow for left/right turns not putting stress on the wiring?

I can tell you the backbone does not give you a lot of space to work with especially once you get those molex connectors back in there. No way to organize all of the wiring in there.

If I thought I wouldn't compromise the backbone, I'd cut a large access panel in the top of it.