Internal wiring is giving me hell
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Cruiser
Joined: Feb 2011
Posts: 104
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Internal wiring is giving me hell
I know there is how to's and what not already on internally wiring new apes, but my problem is getting the wires to internally thread through the damn bars. I've tried using the string that came with the new bars but it snapped on me on both ends ha. I can't seem to get the wiring to get past that first bend it just keeps jamming up on both sides of the bars. Just was wondering if anyone has some tricks or ideas to help out. I may just have to get some wire or twine and muscle them through. Thanks again guys.
Here is a pic of the new bars just bolted up after I took everything apart so it'd be an "easy" install haha. No idea why the pic won't post upright either
Here is a pic of the new bars just bolted up after I took everything apart so it'd be an "easy" install haha. No idea why the pic won't post upright either
Last edited by Po2387; Jan 5, 2013 at 11:51 AM.
Cruiser
Joined: Aug 2010
Posts: 208
Likes: 1
From: Minnesota
Try a speedometer cable
What I have used to do internal wiring is an old speedometer cable, taped the wiring to it, then feed the cable into the bar. Speedometer cables are nice because of being metal that is flexible yet rigid enough to handle you pushing through the wiring. Same idea s a sewer snake plumbers use, so to speak. This has it's own challenges since you never know what kind of weld spatter or other crap is in the bar to block easy movement. Patience and finesse goes a long way in getting the internal wiring done. Hope this helps! Cheers!
Road Master
Joined: Oct 2011
Posts: 1,243
Likes: 14
From: Right where I belong!
I had a helluva time with mine also, but this is what I did that worked best in the end.
Use twine, washer tied to one end, drop in at the top and use a vacuum to suck it out at the bottom. Use heat shrink tubing on your electrical wires, but try to stagger your pins as good as you can. One your wires are heat shrinked, attach the other end of the twine to them and pull from the bottom. You can also spray a little bit of grease down the inside of the bars to help. Repeat for the other side of the handlebars.
Good luck!
Use twine, washer tied to one end, drop in at the top and use a vacuum to suck it out at the bottom. Use heat shrink tubing on your electrical wires, but try to stagger your pins as good as you can. One your wires are heat shrinked, attach the other end of the twine to them and pull from the bottom. You can also spray a little bit of grease down the inside of the bars to help. Repeat for the other side of the handlebars.
Good luck!
I know there is how to's and what not already on internally wiring new apes, but my problem is getting the wires to internally thread through the damn bars. I've tried using the string that came with the new bars but it snapped on me on both ends ha. I can't seem to get the wiring to get past that first bend it just keeps jamming up on both sides of the bars. Just was wondering if anyone has some tricks or ideas to help out. I may just have to get some wire or twine and muscle them through. Thanks again guys.
Here is a pic of the new bars just bolted up after I took everything apart so it'd be an "easy" install haha. No idea why the pic won't post upright either
Here is a pic of the new bars just bolted up after I took everything apart so it'd be an "easy" install haha. No idea why the pic won't post upright either
Elite HDF Member
Joined: Dec 2009
Posts: 4,598
Likes: 14
From: navarre ohio
i fished a single piece of wire through the bars. cut or slide the black plastic off the switch wires and rewrap the wires together with electrical tape to make it a lot tighter. tape the single wire to the switch wire bundle, and it will pull rite through..
that ball chain looks like a good idea..
that ball chain looks like a good idea..
Road Master
Joined: Oct 2007
Posts: 1,213
Likes: 1
From: Hot Springs Village AR
I used weed eater line and tape it in a hook so it wont pull out and taper your wires so its not a big clump of wires, I did T bars talk about a bitch apes are easy
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Cruiser
Joined: Feb 2011
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Awesome ideas! Most of them I have the supplies in my shop so I am going to get on it my next day off. Thank again!
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Outstanding HDF Member
Joined: Nov 2009
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From: Sonoma County, CA
I've had pretty good success on two separate sets of bars. I used a heavy nylon string with a washer tied on the end to get the string fished through. I did not mount my bars so I could tip the bars back and forth to get the washer and string fished through first. Then as someone else mentioned, try and stagger the pins as best you can. I used electrical tape with a very long tapered wrap. Make sure to put a small knot in the end of the string and really secure the knot and string in multiple wraps of the tape. Make sure to have the string and primary pull location all the way to the end of the wires and tape. That way when you slide it up to the bends, you can slowly pull the tape and wires around the corners. This is where patience comes in. You may have to work it back and forth a bit to help everything make the bends. Again, getting the wires and tape all VERY secure and tapered is important. You don't want the string to pull out half-way through the job.
This has always worked well for me, but after I did both sets of bars, I saw other postings about using a beaded type of chain. I'm sure that method is pretty good too. Main thing is the connection to the wires and how well it directs the wires through the various bends. From the look of your bars, I would think they should be pretty easy (if there is such a thing when wiring internally) lol. Good luck.
This has always worked well for me, but after I did both sets of bars, I saw other postings about using a beaded type of chain. I'm sure that method is pretty good too. Main thing is the connection to the wires and how well it directs the wires through the various bends. From the look of your bars, I would think they should be pretty easy (if there is such a thing when wiring internally) lol. Good luck.
