Internal Handlebar Wiring Help...
Outstanding HDF Member
Joined: Nov 2007
Posts: 2,289
Likes: 22
From: Beautiful Downtown Burbank
If you dont want to use the pull chain, I use a fishing line and a 1/4-20 nut tied on the end. Just drop it in one hole, shake the bars, and it falls out the other. Tie the line to the wiring harness, tape up the loose wire ends, and pull it back through. Takes about 10 minutes per side.
i also on really tricky bars will take some string, block off al lthe holes int he bars and then blow line though with a air compressor, works awesome, spray some soapy water in the bars to help the wires slide easier in there
Ultimate HDF Member
Joined: Dec 2008
Posts: 5,120
Likes: 17
From: Indiana
Understand that in the hard curves like the top angles on our bars, but in the rounded portion it's not going to matter. The shrink wrap is long enough that it still covers the wires through the top angles. I tried to route the wires with the mesh wire loom on it, but it just wouldn't fit very easy let alone staying put!! If they were 1 1/4 inch bars or all rounded bendsi t would have definitely been a lot easier. My last bars they were bare for a year and no issues and no chaffes on the wires when I removed them. One side I had the loom on, but the other side with the 8 wires was just to thick to get through.
Last edited by JaronB; Sep 17, 2010 at 02:14 PM.
Ultimate HDF Member
Joined: Dec 2008
Posts: 5,120
Likes: 17
From: Indiana
I did that last time, but all I had was cotton string and the stupid string kept breaking. I read somewhere on here that you used the chain and man so much better this time around.
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Thread Starter
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Intermediate
Joined: Sep 2010
Posts: 34
Likes: 0
From: FTW, TX
Well...Finally got it done. I tried both the chain and fishing line, actually broke both. The fish line was not strong enough (kinda old and had been sitting around awhile), so gave up on that. Chain worked great, but managed to break it too. Was able to feed the wires thru enough to grab the chain again, but this time it pulled out of the tape. Then I had hell getting the wires back out and the tape got lodged in the bars. Man, I tried everything to get it out. Finally had to use water pressure to push it to the bottom. So...an hour later I redid it all and got the wires fed through the bars and...biggest trick...LOTS OF LUBE! Everything is back on and running good. Thanks for all the guidance. I'll post a pic on Sunday...lighting in the garage sucks!
Ultimate HDF Member
Joined: Dec 2008
Posts: 5,120
Likes: 17
From: Indiana
Nice, just finished mine tonight too!! I'll get better pics later as well!! Yea you gotta put the tape pretty tight on there!! I didn't use any lube, but I'm sure it would have helped. These are 16's vs the first 15" version. Pushing the limits on cables, but works!!
