wiring inside handlebars
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Intermediate
Joined: Oct 2009
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From: florida
wiring inside handlebars
hey guys...i ordered my new burly apehangers yesterday along w/a wiring extension kit (oem color coded wires, connectors, heat shrink etc.) any tips would be appreciated. It seems to me that i will want to stagger my cuts/splices to avoid a big bundle trying to go thru the hole.
2001 roadking classic, 16" burly apes @ 1.25" o.d....lots of room in the headlight nacelle for extra wiring.
2001 roadking classic, 16" burly apes @ 1.25" o.d....lots of room in the headlight nacelle for extra wiring.
Extreme HDF Member
Joined: Nov 2007
Posts: 14,670
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From: East of the Sun, West of the Moon
using an air compressor, blow a couple of pieces of string through each end of the handlebars to the exit point. this will certainly aid in getting your wires where they need to be.
Ultimate HDF Member
Joined: Jan 2007
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From: back home in Michigan
Did your extension kit come with pins? You can make up a plug with pins and all avoiding any solder joints inside of your bars. I was advised to avoid that if possible because any joint like that is a potential problem and you don't want problems with your wiring while on the road. I know people who say screw it and solder stuff, and if its necessary then what do you do. But I try to avoid it anytime I can.
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Intermediate
Joined: Oct 2009
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From: florida
thanks Glideride, yea it came w/pins...what a great kit. I didn't know that you can take the individual wires/pins out of the duetsch plugs in the wiring harness like that...sure glad i didnt start cuttin ! I will say that i thought a 12" extension kit was gonna be overkill but if anybody is buying a kit, measure carefully...it will take more wire than you think to go up and over the top bend of the handlebars.
Ultimate HDF Member
Joined: Jan 2007
Posts: 8,750
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From: back home in Michigan
Yep, better to leave it long (if it will tuck away ok) because the extra length might serve you well down the road. Just take your time and do it right the first time. No need to get antsy and hurry the job up. Sounds like you have the right frame of mind for that. Good luck.
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