Looking to do some internal wiring

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Feb 28, 2012 | 07:27 AM

#11

SC-Longhair

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Joined: Feb 2008

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From: Passaic County, NJ

I did a set of z-bars during the summer on my bud's sporty. The word "suck" doesn't begin to cover it.

If you can buy them pre-wired, that'd be the way to go. I normally don't suggest that but after having done a set, I'm all for paying the fee to have it done for you.

Feb 28, 2012 | 09:05 AM

#12

Mr.Guns

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Joined: Oct 2011

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From: Richlands, NC

I used cable lube. Same stuff I use for pulling Networking cables through conduit. Worked REALLY well, and it wipes right off when you're done. Available at Lowe's, Home Depot, etc... Comes in bottles like 80w-90 would, just squirt it on all cables and wires, even some down the bars. Cut actual PULLING time down a LOT.

Feb 28, 2012 | 11:31 AM

#13

ek1

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Joined: Jan 2012

Posts: 24

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From: Buffalo,N.Y.

Well you picked out about the hardest bars to to pull thru. I have pulled thru Z's but not that complicated, I used a rare earth magnet to make the 90 bends with a small nut on the lead wire. I don't even know if that will help you.Might sound silly but blow thru the bars first to see if they have been slugged.GOOD Luck

Feb 28, 2012 | 12:14 PM

#14

matte

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Joined: Apr 2006

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From: Texas

I think I'm less concerned about routing as I am the task of rewiring. am the task of rewiring. I may leave the four cables I mentioned as braided and route the button controls through the bars. My only concern is the current braided wires may be too long.

Feb 28, 2012 | 04:57 PM

#15

MCSarge

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Joined: Jul 2006

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From: Michigan

When I do the wires thru the bars the first thing I do is cut the factory sheathing off and use the smallest heat shrink tubing that will fit all the wires and shrink it down. I usually leave about 2 inches of factory sheathing by the controls to add a little extra chaffing protection at the top. I have used baby powder and wire lube (not at the same time) and both work well. Z bars are a pain with just the wires so I don't know if I'd want to try the cables too. Good luck on your project.

Feb 29, 2012 | 10:38 AM

#16

R_W_B

Road Captain

Joined: Oct 2010

Posts: 683

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From: Florida

When I did my TBars the wires just would not go thru with all of them. So I only pulled 4 wires at a time, having a pull string knot going each way. Worked out good.

I used masking tape, no sticking mess on the wires when you remove it.

Mask off all other holes except the in and out of your pull and suck the string thru instantlly with a shop vac. Just put over one end of the bars.

Here's a video I did of one part of the install.

http://www.youtube.com/watch?v=-vkoq6kLlqw

Last edited by R_W_B; Feb 29, 2012 at 10:42 AM.

Mar 3, 2012 | 12:50 PM

#17

matte

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From: Texas

Thanks for all the tips guys. As I am looking at what I have to work with, it appears I will have to take the tank off to get at the handlebar control wires to make this work. Should I do it this way or is there a way the wires easily come out of the handcontrols?

Mar 3, 2012 | 03:21 PM

#18

matte

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From: Texas

So after alot of feeding and pulling, I found the handcontrol plugs. Obviously these are too big to run through a handlebar. Do most people cut their wires....run em through and sodder em back together? Not particularly great on the electrician side...but trying to find the best way to tackle this.