internal wiring handlebars
Road Warrior
Joined: Nov 2010
Posts: 1,251
Likes: 30
From: Ashburn, VA
And there is nothing wrong with that, I just feel that it adds more points of connection failure. It's best to keep the cutting/shrinking points to a minimum, when possible, but if its done right on each connection, there should be no issues whether there is one connection or one hundred connections.
Thread Starter
|
Intermediate
Joined: Jan 2013
Posts: 36
Likes: 0
From: overland park, KS
Thanks for the input guys. I actually went to this computer micro center today to look for electrical wire that is thinner than the wire i used from homedepot and saw a variety of those pins for sale and adapters. Not sure if it will work for the guys who said they broke theirs, but I figured it was worth a try before taking a trip to the dealership. Two follow up questions: What are the gauges of wire used in these connections? and will the WD really have a serious impact on the wires? I was able to get 14 gauge through with all of the wires but it is a really tight fit. I may try and rewire them with thinner wire....especially if all of these connections are going to dry out and crack 
the wiring must be able to handle 12v. going thinner is not really so much as better. do you have them in some type of covering? shrink wrap or cable cover? if not i would at least flush them before putting them back on, i have seen some pretty nasty wires pull from inside bars that where lubed with WD during install, the cable covers hardened and cracked exposing wires and shorting out on the bars. *i will say this was also 2 years after it was originally done so i do not feel you have anyting to worry about right NOW, but down the line it may or may not become an issue. just something to beware of*
on the wiring, again do not just go thin make sure it is 12v approved, i like to stretch my lines, (solder in my extension) then wrap them with shrink wrap so that they are 1 solid line... baby powder the shrink wrap cover and put some down the bars... drop a pull chain like you use on a house fan down from the grip to the center, attach string... do both sides... then tie the string to the wire, run some electrical tape around that so the pull is smooth, and pull it though. after both sides are though, blow out the bars to get out the left over baby powder and plug back into the connectors. if you drill the bars yourself that is no problem just be sure you can pull a cotton ball though and not have it get hung up, any sharp edges will wear though and short out the bike.
on the wiring, again do not just go thin make sure it is 12v approved, i like to stretch my lines, (solder in my extension) then wrap them with shrink wrap so that they are 1 solid line... baby powder the shrink wrap cover and put some down the bars... drop a pull chain like you use on a house fan down from the grip to the center, attach string... do both sides... then tie the string to the wire, run some electrical tape around that so the pull is smooth, and pull it though. after both sides are though, blow out the bars to get out the left over baby powder and plug back into the connectors. if you drill the bars yourself that is no problem just be sure you can pull a cotton ball though and not have it get hung up, any sharp edges will wear though and short out the bike.
Thread Starter
|
Intermediate
Joined: Jan 2013
Posts: 36
Likes: 0
From: overland park, KS
the wiring must be able to handle 12v. going thinner is not really so much as better. do you have them in some type of covering? shrink wrap or cable cover? if not i would at least flush them before putting them back on, i have seen some pretty nasty wires pull from inside bars that where lubed with WD during install, the cable covers hardened and cracked exposing wires and shorting out on the bars. *i will say this was also 2 years after it was originally done so i do not feel you have anyting to worry about right NOW, but down the line it may or may not become an issue. just something to beware of*
on the wiring, again do not just go thin make sure it is 12v approved, i like to stretch my lines, (solder in my extension) then wrap them with shrink wrap so that they are 1 solid line... baby powder the shrink wrap cover and put some down the bars... drop a pull chain like you use on a house fan down from the grip to the center, attach string... do both sides... then tie the string to the wire, run some electrical tape around that so the pull is smooth, and pull it though. after both sides are though, blow out the bars to get out the left over baby powder and plug back into the connectors. if you drill the bars yourself that is no problem just be sure you can pull a cotton ball though and not have it get hung up, any sharp edges will wear though and short out the bike.
on the wiring, again do not just go thin make sure it is 12v approved, i like to stretch my lines, (solder in my extension) then wrap them with shrink wrap so that they are 1 solid line... baby powder the shrink wrap cover and put some down the bars... drop a pull chain like you use on a house fan down from the grip to the center, attach string... do both sides... then tie the string to the wire, run some electrical tape around that so the pull is smooth, and pull it though. after both sides are though, blow out the bars to get out the left over baby powder and plug back into the connectors. if you drill the bars yourself that is no problem just be sure you can pull a cotton ball though and not have it get hung up, any sharp edges will wear though and short out the bike.
Thread Starter
|
Intermediate
Joined: Jan 2013
Posts: 36
Likes: 0
From: overland park, KS
I finally got them done. I used a four color wire combo pack i purchased at advanced auto which is made to wire trailers. It comes in attached 4 wire clusters. This was the key to saving me hours. The wires being attached to each other made it very simple to pull through the bars. I used a black gasket sealant to make sure everything was completely water proof. I also rewired my turn for a more stealthy look. I bent some L brackets from Home Depot and attached the turn signals to the headlight mount. I put up some pics.
Elite HDF Member
Joined: Aug 2006
Posts: 3,759
Likes: 1
From: Republic of Texas
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Thread
Thread Starter
Forum
Replies
Last Post