Question about internal wiring
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Joined: Aug 2006
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From: Orange County, CA
Question about internal wiring
I would like to do internal wiring on my bars ('06 lowrider) but I dont' know if this can be done safely with stock bars.
The dealer said they've done it - but on larger touring model, one snapped in half (the entry hole weakened the center part of the bars too much). They normally install larger diameter bars for internal wiring.
The lowrider has a wider clamp on the bars, so it may be a stronger setup - but has anyone done this?
I would relocate the turn signals to the triple trees (a little less wiring to run - so smaller holes).
Any experiences would be appreciated. Thanks.
The dealer said they've done it - but on larger touring model, one snapped in half (the entry hole weakened the center part of the bars too much). They normally install larger diameter bars for internal wiring.
The lowrider has a wider clamp on the bars, so it may be a stronger setup - but has anyone done this?
I would relocate the turn signals to the triple trees (a little less wiring to run - so smaller holes).
Any experiences would be appreciated. Thanks.
Outstanding HDF Member
Joined: Apr 2006
Posts: 2,537
Likes: 21
RE: Question about internal wiring
One of the problems with making your stock bars capable of internally wired controls is, as you have been told, is the possibility of weakening the bars themselves.....
Take off too much material and you raise the possibility of them breaking at the holes that you had to make for the wires.....
If you tale a look at bars that are SPECIFICALLY designed for internal wires, you will notice that they are much beefier and the drillings are not near the stress points....
I have had to do 1 bike as per the customer wanting the stock bars drilled out.....
The Svc Mgr asked him to sign a waiver, releasing our shop from any liabilities down the road, as it was not a mod that we encourage.....
Customer signed it, and about 6 weeks later came back with the right side of the bar broken off... (Pulling on the bars to back up...)
Do yourself a favor, invest in the CORRECT type of bars, you wont regret it, and ensure that you STAGGER your Solder/Shrinked joints so they fit better....
Take off too much material and you raise the possibility of them breaking at the holes that you had to make for the wires.....
If you tale a look at bars that are SPECIFICALLY designed for internal wires, you will notice that they are much beefier and the drillings are not near the stress points....
I have had to do 1 bike as per the customer wanting the stock bars drilled out.....
The Svc Mgr asked him to sign a waiver, releasing our shop from any liabilities down the road, as it was not a mod that we encourage.....
Customer signed it, and about 6 weeks later came back with the right side of the bar broken off... (Pulling on the bars to back up...)
Do yourself a favor, invest in the CORRECT type of bars, you wont regret it, and ensure that you STAGGER your Solder/Shrinked joints so they fit better....
Outstanding HDF Member
Joined: Aug 2005
Posts: 2,042
Likes: 0
From: Brunswick, MD
RE: Question about internal wiring
I did the internal wiring on stock mini apes and I drilled a 3/4 inch hole on the grip ends and a 7/8 inch in the bottom middle between the risers and I have noticed no weakness at all! I have pulled on them hard too as I have to backup through some grass to get the bike from the shed. I already had my signals relocated and didn't have to worry about them wires. Just for your info my cycle had 8 wires on each side that I had to splice. Take your time and you'll be OK.
If you wanna ask me any question feel free to pm me or email me.
Here's a pic
If you wanna ask me any question feel free to pm me or email me.
Here's a pic
Seasoned HDF Member
Joined: Dec 2004
Posts: 11,068
Likes: 1,473
From: Texas! Ya mean there's someplace else?
RE: Question about internal wiring
Something to maybe think about when doing this modification is to make them into two-piece bars. Then you can run the wires through them without the worry of drilling a hole and weakening them. The old factory bars all used to be two-piece so the internal throttle and wiring could be easily run. As long as your top cover is a one-piece type, the fact that the bars are cut in two doesn't show.
RE: Question about internal wiring
I agree with shovelheadbob..I would recommend just buying a set with pre-drilled wiring holes. Bars dont cost to much and saftey is PRICELESS. Ive installed MANY bar conversions. When doing so, lift tank up & remove left & right connectors..take apart plug..(make diagram) and then you can add wire length to the wiring & re-use the electrical connector ends to reinstall into your factory plugs, makes for a clean install. Do use good connectors & heat shrink. You can use guitar string to pull wiring threw the new bars if the bars dont already come with a string tied threw them--Using a string and blowing it threw the bars with a blow gun is another way to get the wiring pulled threw the new bars. GOODLUCK
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