Wire extensions
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Road Warrior
Joined: Apr 2011
Posts: 1,905
Likes: 66
From: Hartford, AL
Wire extensions
This is for a 2019 Heritage Classic 114. I am going to replace the stock handlebar riser with a HD product but I'll need bar wiring extensions. There is virtually no slack in the existing wiring and when I pulled the bars off could only get 1/2" to maybe 1" clearance from the riser. Brake lines and clutch have enough extra to not need longer cables.
I did some research and found a couple videos about handlebar and wiring extensions. All were replacing the bars so that meant removing the stock wiring and pulling new through the bars. Simple enough but in my case I'm not replacing bars, just putting on risers so the stock wiring can remain internal to the bars. Looks like I need to add the extensions to the bottom end which means pulling the bib and tank. Just a bunch of extra work which isn't overly complicated, just time consuming. I can't imagine what the dealership would charge in labor to R&R all those parts.
From what I can tell it seems that if done that way I can disconnect the wiring in the "tank" area, pull up the slack through the conduit and triple tree, install risers and then I can accurately measure how much extension is needed, order and install. OR get ample length extension and route the extra under the tank area. My thoughts are that if the risers come up 1.5", back 1.5" from stock, anything over 3" would work. I have seen 4" and 6" extensions in catalogs so figure either will be enough. I'll need turn signal/switch extensions L and R and TBW extensions, all about the same length.
For those who have done this, does this sound correct???
Thanks.
I did some research and found a couple videos about handlebar and wiring extensions. All were replacing the bars so that meant removing the stock wiring and pulling new through the bars. Simple enough but in my case I'm not replacing bars, just putting on risers so the stock wiring can remain internal to the bars. Looks like I need to add the extensions to the bottom end which means pulling the bib and tank. Just a bunch of extra work which isn't overly complicated, just time consuming. I can't imagine what the dealership would charge in labor to R&R all those parts.
From what I can tell it seems that if done that way I can disconnect the wiring in the "tank" area, pull up the slack through the conduit and triple tree, install risers and then I can accurately measure how much extension is needed, order and install. OR get ample length extension and route the extra under the tank area. My thoughts are that if the risers come up 1.5", back 1.5" from stock, anything over 3" would work. I have seen 4" and 6" extensions in catalogs so figure either will be enough. I'll need turn signal/switch extensions L and R and TBW extensions, all about the same length.
For those who have done this, does this sound correct???
Thanks.
Club Member
Joined: Jul 2013
Posts: 468
Likes: 222
From: NorCal
I found the easy way was to use KST Kustoms wire extensions.
https://www.kstkustoms.com/collectio...resent-touring
https://www.kstkustoms.com/collectio...resent-touring
Stellar HDF Member
Joined: Apr 2016
Posts: 3,282
Likes: 2,077
From: Masshole
Why not just buy new longer cables? Very little difference in price and you'll also not have to worry about the extra connectors. I personally prefer Gorilla Cables out of CA. Fantastic customer service and very reasonably priced. Have used them both for my SGS and a friends RK.
Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,897
From: Bedford UK
Forget the fact that you are using the same bars - pretend that after you have removed them, they are new and go from there! Follow suggestions above as if you are making a fresh start. Wiring internally with extensions relies on staggering the joins, so you don't get a big bunch of connections in one place. Trying to extend your existing wiring outside the bars will create an ugly sight I suspect. chopper man's suggestion above looks a good one to me....
Intermediate
Joined: Jul 2019
Posts: 34
Likes: 21
From: Napa, CA
I don't see a Namz "kit" per se on their website, but I can get 8" extensions for TBW, Turn signals, and Can/Bus wires, and I think that should all work.
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