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

 

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

 

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.

 

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.

 

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.

 

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.

 

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.

 

I actually swapped from 16in apes down to 13's, so I had plenty of slack from the bars to the neck.

BTW, a big thanks to you SC! Your wiring vid got me through the disassembly of the Molex connectors without anyone getting hurt!!

 

Not a problem. Glad it helped you out.