Ran into an issue when installing my factory 47 bars. Amazing bars. I purchased the 12” bars so I did not have to run aftermarket wiring, however when I went to ride the throttle didn’t work, the connector on the throttle wire inside the bars came apart when pulling them through. So I took it all back apart and super glued the connector so it would not come apart again. I wish I knew to do that before the first pull. It would have saved me doing it twice

 

Best tip I’ve got for anyone on their first install is to watch KST Kustom's install video no matter whose bars you are installing.

All good stuff.

 

Many good videos to be found with great tips to ease install. KST, ride it wrench it, skydude to name a few.
my suggestion for the the dreaded green plug on the TBW is to de-pin the plug. You can remove the plug from around the pins leaving the male and female connectors intact. Then just individually re-pin each connector with heat shrink then cover all 6 wires with another heat shrink (put larger heat shrink over the wires first then re-pin)
that green plug is the bane of many bar installs.

 

Excellent info here , doing my bars now , Weeboy , I'll take your advice and de-pin that connector , I can see where it could get in the way . I also might drop a little solder on each pin for added security .

 

I said de-pin but unlike the molex you can’t de-pin them they are integrated into that plug. I had to use pliers and gently crush the plug and remove the plug from around the pins. Very easy to do and then you don’t have to worry about accommodating that plug along with the other 12 wires through that bar. Solderings not really necessary if you individually heat shrink them but won’t hurt either as long as the solder will stick to the pins. Remember to check corresponding wire colours before disconnecting. They are different on either side of plug.
good luck with the install and keep us posted.

 

Great , thanks for that , I have the switch packs on the bench now , wires already extended , I will look at that connector tomorrow and see what I can do .

 

I also used nylon wire sleeving after removing OEM wire wrap. 1/4” for TBW and 3/8” for bar controls. Lubed up with Vaseline made running wires much easier, protected the wires and also gave the end result a nice professional look.

 

Sorry I’ll add just one more thing. With the control wires, stagger the pins so when you tape them they come to more of a point. Easier to guide them thru the bar. Not as much an issue with the TBW 6pins but the 12 and 14 is pretty thick. Just makes life easier. I found all these out the hard way...but it’s done, looks and works great and saved a boat load of $ doing it myself.

 

Another tip. Do not "pull" wires thru Monkey bars or any bars like them. Use a "push" from the switchpack side with a very light "pull" from center bar to remove the slack you just pushed in to the bars. It will stop the damage to the wires going thru the point. Pulling lube helps significantly as well, you can get it at lowes, home depot etc.

 

Thanks for all the tips guys , yes , I'm using a nylon sleeve ( 2 sizes ) to cover my wires , the string I'm using is a braided line , like one you would use for a chalk line . With all the information I've collected and the fsm , thing should go quite smoothly , and I'm taking lots of pics too .

Thanks op for starting this thread , because of you , I've been given great advice , very much appreciated ,