Internal Handlebar Wiring Issues
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From: Behind the cheddar curtain
Internal Handlebar Wiring Issues
Happy Memorial Day to everyone and thanks to all that serve and that have served.
I've got an 04 FatBoy that has a very uncomfortable set of beach bars with internal wiring on it that I would like to replace but I cannot get the wires to pull through the old bars. I am at my witts end to the point of tossing things around in the shop.
Any assistance would be greatly appreciated. Guessing I'd probably need help with running them in the new bars as well .....
Thanks,
The Doberdewd
I've got an 04 FatBoy that has a very uncomfortable set of beach bars with internal wiring on it that I would like to replace but I cannot get the wires to pull through the old bars. I am at my witts end to the point of tossing things around in the shop.
Any assistance would be greatly appreciated. Guessing I'd probably need help with running them in the new bars as well .....
Thanks,
The Doberdewd
Outstanding HDF Member
Joined: Apr 2012
Posts: 2,938
Likes: 30
From: North Florida
Happy Memorial Day to everyone and thanks to all that serve and that have served.
I've got an 04 FatBoy that has a very uncomfortable set of beach bars with internal wiring on it that I would like to replace but I cannot get the wires to pull through the old bars. I am at my witts end to the point of tossing things around in the shop.
Any assistance would be greatly appreciated. Guessing I'd probably need help with running them in the new bars as well .....
Thanks,
The Doberdewd
I've got an 04 FatBoy that has a very uncomfortable set of beach bars with internal wiring on it that I would like to replace but I cannot get the wires to pull through the old bars. I am at my witts end to the point of tossing things around in the shop.
Any assistance would be greatly appreciated. Guessing I'd probably need help with running them in the new bars as well .....
Thanks,
The Doberdewd
Road Captain
Joined: Apr 2013
Posts: 600
Likes: 10
From: Rochester, NY
As already stated you have to remove the connectors in order to pull the wires through. It's always a good idea to take pictures and label the wires to make reassembly easier/possible. Also don't pull to hard. You can damage the wires. It will help if you push from one end while you pull from the other.
A chain works good for fishing wires into the bars. Just drop the chain through the bars, tape the wires to the chain and pull them through. You can get the right sized chain at any hardware/big box home store. When I changed my bars i used an old speedometer cable taken out of it's protective sleeve. It was more rigid than a chain but still easily followed the bends in the bars.
Good Luck!
A chain works good for fishing wires into the bars. Just drop the chain through the bars, tape the wires to the chain and pull them through. You can get the right sized chain at any hardware/big box home store. When I changed my bars i used an old speedometer cable taken out of it's protective sleeve. It was more rigid than a chain but still easily followed the bends in the bars.
Good Luck!
Thread Starter
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Novice
Joined: Dec 2014
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From: Behind the cheddar curtain
I have the grips off, switches disassembled, levers removed, tank slid back, wiring unplugged and individual wires removed from plugs. Wiring is run thru a sheath then into the bars. I'm ready to cut n toss the sheath .... not sure wires will survive without them.
As already stated you have to remove the connectors in order to pull the wires through. It's always a good idea to take pictures and label the wires to make reassembly easier/possible. Also don't pull to hard. You can damage the wires. It will help if you push from one end while you pull from the other.
A chain works good for fishing wires into the bars. Just drop the chain through the bars, tape the wires to the chain and pull them through. You can get the right sized chain at any hardware/big box home store. When I changed my bars i used an old speedometer cable taken out of it's protective sleeve. It was more rigid than a chain but still easily followed the bends in the bars.
Good Luck!
A chain works good for fishing wires into the bars. Just drop the chain through the bars, tape the wires to the chain and pull them through. You can get the right sized chain at any hardware/big box home store. When I changed my bars i used an old speedometer cable taken out of it's protective sleeve. It was more rigid than a chain but still easily followed the bends in the bars.
Good Luck!
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