Tricks to tread wires inside handlebars?
Grand HDF Member
Joined: Dec 2007
Posts: 4,999
Likes: 55
From: Bay Area
RE: Tricks to tread wires inside handlebars?
5 wires is easy, try 28, but wrap with tape, a long thin lead pull wirewith some liqued dish soap will help. you have to be patient while pushing and pulling the loom thru. Be carefule of sharp edge on the ends or hole in bars, so it doesnt chaf the wires bare. Now I know why the dealer charges a grand to install bars.
Road Warrior
Joined: Jul 2007
Posts: 1,462
Likes: 22
From: Delaware
RE: Tricks to tread wires inside handlebars?
I have ran wires through bars on a few bikes. Ifirst fished a thin piece of welding wire to use as a pull string. Then I taped the wires onto the welding wire, coated the hell out of it with wire pulling lube, pulled on one end and pushed on the other. It works better with 2 people. One pushing and one pulling. If that doesnt work because its too tight.... Pull 3 wires then take one of the 3 and tape it onto 3 more and pull them through. Theres your 5. I used a ton of wire pulling lube. It helped a lot. Then, and most important, take a multi-meter and test each wire to the bar (ground) To make sure you didnt nick a wire.
I did a VTX that had 12 wires through a hole smaller than a pencil. Goto Home Depot and buy wire pulling lube. Its great for doing this
I did a VTX that had 12 wires through a hole smaller than a pencil. Goto Home Depot and buy wire pulling lube. Its great for doing this
Ultimate HDF Member
Joined: Dec 2007
Posts: 8,642
Likes: 6
From: Forest Lake, Mn
RE: Tricks to tread wires inside handlebars?
No problem.
2 ways.
1) Get yourself a length of plumb line (The kind for laying out concrete forms, etc. The yellow or green cord) Now, use a small vacuum clnr, tape the hose over one end of the handlebar or over the "opening" you want one end of the line thru.Crank up the vac, feed the cord/line from the other end, when it is into the vac hose a few inches, voilla, you have something to tape the wires to, and pull them thru the bars.
2) Basically the same, 'cept tie a small lead fishing weight to the cord/line, tip the bars up and down (works if bars are off bike ONLY
unless you are a BIG bastud and cantip and holda bike up). Feed it thru the bars, and when it comes out the other end, voilla, again. Tape your wires to the cord/line, and pull away.
The vac works the best, tho. Been doing it for over 30 years. And it works for pulling wires thru conduit if you are in the building trades, too.
Have FUN!!!!!! And good luck with your project. Always GREAT to accomplish it, isn't it?
2 ways.
1) Get yourself a length of plumb line (The kind for laying out concrete forms, etc. The yellow or green cord) Now, use a small vacuum clnr, tape the hose over one end of the handlebar or over the "opening" you want one end of the line thru.Crank up the vac, feed the cord/line from the other end, when it is into the vac hose a few inches, voilla, you have something to tape the wires to, and pull them thru the bars.
2) Basically the same, 'cept tie a small lead fishing weight to the cord/line, tip the bars up and down (works if bars are off bike ONLY
unless you are a BIG bastud and cantip and holda bike up). Feed it thru the bars, and when it comes out the other end, voilla, again. Tape your wires to the cord/line, and pull away. The vac works the best, tho. Been doing it for over 30 years. And it works for pulling wires thru conduit if you are in the building trades, too.
Have FUN!!!!!! And good luck with your project. Always GREAT to accomplish it, isn't it?
Road Master
Joined: Mar 2007
Posts: 980
Likes: 0
From: Stafford, Virginia
RE: Tricks to tread wires inside handlebars?
I've used single-conductor 14 (or larger) wire as a guide with the other wires wrapped or taped to it. A metal coat hanger works too, but with the wire the insulation keeps you from scratching the handlebar.
Another trick is to run a piece of heavy string up the bar (shoe-lace works) then tie or wrap wires and pull through.
I know it can get aggravating. Good luck!
Another trick is to run a piece of heavy string up the bar (shoe-lace works) then tie or wrap wires and pull through.
I know it can get aggravating. Good luck!
Cruiser
Joined: Mar 2008
Posts: 174
Likes: 0
From: Clifton, ME
RE: Tricks to tread wires inside handlebars?
+1 on the single wire...ive also had luck with weedwacker string in similar conditions
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Outstanding HDF Member
Joined: Sep 2007
Posts: 2,782
Likes: 7
From: NC
RE: Tricks to tread wires inside handlebars?
i dicked around with running my wires for hours...finaly went to my indy and he did it in 30min for $30...he said his trick was to use an old speedo cable...basically like everyone else is saying, you need something flexible yet strong to run through the bars first, then tie the wires to it
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Intermediate
Joined: Dec 2007
Posts: 35
Likes: 0
RE: Tricks to tread wires inside handlebars?
all good advice.I just did my 08 RKC. I put on a set of Wild 1 bars, 1 1/4, although they are 1 inch between the risers......and there are a lot of wires, especially on the throttle side. The throttle side had 2 seperate looms. Anyway......I used a piece of nylon braided line, like what was mentioned for laying out concrete forms, etc.....bright lime colored. I used compressed air to blow the string through, then taped the line along side the wire harness for about 3 or 4 inches. Gotta wrap the tape very tightly, with a knot on the end of the string to help keep it from pulling through the tape. Greased the wire harness with teflon grease.....didn;t think about Home Depot to get wire pulling lube. (good idea). It also helps to warm the wires up with a blow dryer or some other "not to hot" heat source. At work...Ford truck plant.....they keep most of the wireing harnesses in a heated container prior to pulling them during assy. of new trucks. I think I had something like 17 wires in those 2 harnesses, with the electronic throttle harness having a large connector in the middle of it.....it was kinda a baitch to pull.....thought it was going to pull sealed wired out of that connector.
Stellar HDF Member
Joined: Jul 2006
Posts: 3,029
Likes: 449
From: Michigan
RE: Tricks to tread wires inside handlebars?
All good advice, one thing I will add is cut the factory sheathing off the wires and put on the smallest diameter of heat shrink tubing you can find. When I did the new Street Slammers on my RK I had a heck of a time getting the wires to go around an almost 90 degree bend where the bar attached to the welded on riser. I finally talked to a guy that builds bikes for a tip and that's what he told me to do. I ended up using a 1/4" piece of heat shrink tubing and it worked like a charm. Leave about 2" of the factory cover by the controls to give you extra protection where the wires go into the top of the bars. Good luck on your project and post some pics when your done.
Leave about 2" of the factory cover by the controls to give you extra protection where the wires go into the top of the bars. Good luck on your project and post some pics when your done.