My uncles brother brought his bike into the shop for some work... he wants apes, stereo, clutch spring, fluids, pads, more chrome... so i figured while i had it in here i would take some pics as I go though for the internal wire. I decided this after his old bars (beach bars) where off... sorry i used a cell as a camera but I hope this helps some of you.. these bars where pre drilled so i did not have to drill them.
YES I know this is a road king, but i figured this will help some people on here, for the bobs the plugs are in the frame near the front of the tank

his old set up


FIRST THING... COVER THE TINS!!! we use towels, they are cheap and work!


there is a plug right under the headlight cover, you just unclip the gray and black plugs, then remove the bars, if you pull off the cover on the tip of the plug you can get to the clips to free the wires, i use a small screw driver and ball end allen to push them out
from there
mark how the wires feed into the plugs



after measuring it out, he needed to add 4 inches to his wires... so i cut 4 inch strips (12 of them) to solder in... yes i know you can buy extensions but this is much more solid, they are soldered in, and i do not have to worry about him being stuck on the road somewhere. Then cut your wires and solder in the ext pieces


from there match the color wires up and solder them together


then cut off the excess and shring wrap


then more shrink wrap to keep the wires tight




i then pull down the cable covering and wrap that all with elect tape... no real reason just keeps it clean


to feed the wire i use pull cord from a fan, works awesome.. you can also blow line though with a air comressor but this works just as well. then hook that to the wires, be sure you check to make sure you are feeing the right side of the wires through the right side of the bars. also run the string or in this case pull chain out the very tip of the wires so it will guide the wires though. i also like to use a spray bottle and give it a few sprays of water in there to help it slide, then it will dry up fast enough and no harm is done



after the wires are though, access that chart for the plugs you made and feed the wires back in where they where


then put the bars on... plug in the wires, and start to assemble the rest
you can see Argos (my pup) on guard at the overhead door


i was able to re route the wires so his throttle, and brake lines will still work great but his clutch line needs replaced.
and here ya go... granted it is still open i have a bunch more work to do it it, but i hope this helps some of yall

 

Nice post. I did my bars last summer. It was a learning process with a few headaches along the way. Thank you all for posting up instructionals like this. I searched the forum and youtube for good advice. Wiring along with brake line, clutch and throttle idle cables took about a full day. It would have taken alot longer than that if it weren't for members like you who take the time to pass on knowledge and experience.

 

Great writeup Joe. I wired mine just like this two years ago on my roadking. Nice to see someone with such a professional but homemade attention to detail. Soldering is way better than the extension kits.

I wrote my wiring diagram on note cards too, works great.

 

The first time is always the hardest. When i did my bars i learned a lot after i got them internally wired (with help from joe of course). Then we did my buddys bike and it took about half the amount of time. It may look intemidating... But its actually pretty simple once you figure it out.

 

thanks a lot for this post. i'm gonna save it and it will see good use.

 

Great write up. I did mine the same way, except I also ran the black plastic mesh tube over the wires and through the bars. Hopefully it will help proctect from sharp edges and burrs.

 

Joe, where were you last month when I was doing mine!! Great post tho, I did mine just about the same way, except I didn't need to do the extentions. Great idea on the water for lubing the inside of the bars. Wish I thought of that. What about a little soapy water, might work better. Besides everybody likes a little suds every once and a while!! LOL!!