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Wiring inside your handlebars
Road Warrior
Joined: Feb 2007
Posts: 1,352
Likes: 3
From: Sydney, Australia
RE: Wiring inside your handlebars
Yeah , there were two plugs. The larger rectangular one that had like an 8 or 10 pin plug we eventually figured out after wrecking the first pin but it was the second plug which was a smaller square shaped one with a rubber shroud you had to pull off first that made us give up. Ofcourse the stealer told me some BS on the phone about them having to be done in "a particular order to work" which I thought was complete crap but I'd rather pay a few hundred bucks that ruin or my wiring. If I ever got to watch it being done once I would be confident doing it though...
Thanks for the info!
DeanO
PS: going out to night to try and pry up a little tang for myself
Thanks for the info!
DeanO
PS: going out to night to try and pry up a little tang for myself
ORIGINAL: darkside
Dmac all you need is a small flat tip screwdriver(like the kind used to fix eyeglasses) . When you get the orangewedge fitting off the end of the connector you have to pry up the little tang inside the housing and the wire will pull out easily.
Dmac all you need is a small flat tip screwdriver(like the kind used to fix eyeglasses) . When you get the orangewedge fitting off the end of the connector you have to pry up the little tang inside the housing and the wire will pull out easily.
Road Warrior
Joined: Feb 2007
Posts: 1,352
Likes: 3
From: Sydney, Australia
RE: Wiring inside your handlebars
Secondary locking wedge huh? Hmmmm, no wonder they didn't wanna come out easy My dealers gonna love me next week, got about $8k worth of bits for them to chuck on the bike... woohooo... project almost finished !
DeanO
My dealers gonna love me next week, got about $8k worth of bits for them to chuck on the bike... woohooo... project almost finished !DeanO
ORIGINAL: darkside
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Road Warrior
Joined: Feb 2007
Posts: 1,352
Likes: 3
From: Sydney, Australia
RE: Wiring inside your handlebars
What bars you putting on? I just got a set of Carlini 1.5" freeway bars the same as pn TM's bike (pic below). Can't weight too see what they look like on the bike.
DeanO
[IMG]local://upfiles/24695/B79D3857875D41889BEDC175A6B93096.jpg[/IMG]
DeanO
ORIGINAL: JimmyR
Hi gurus
I'm changing a heap of stuff on my Fatboy, including the bars. So I've drilled the holes in the new bars to put the wiring in, and obviously I'll have to cut the connection plugs off the wires. So how does this work? Do you buy some new plugs that can be easily wired? How do you guys do it??
Thanks!
Hi gurus
I'm changing a heap of stuff on my Fatboy, including the bars. So I've drilled the holes in the new bars to put the wiring in, and obviously I'll have to cut the connection plugs off the wires. So how does this work? Do you buy some new plugs that can be easily wired? How do you guys do it??
Thanks!
Road Captain
Joined: Feb 2007
Posts: 704
Likes: 23
From: on the mud flats on the edge of slum city
RE: Wiring inside your handlebars
ORIGINAL: dmac1968
Secondary locking wedge huh? Hmmmm, no wonder they didn't wanna come out easy My dealers gonna love me next week, got about $8k worth of bits for them to chuck on the bike... woohooo... project almost finished !
DeanO
Secondary locking wedge huh? Hmmmm, no wonder they didn't wanna come out easy
My dealers gonna love me next week, got about $8k worth of bits for them to chuck on the bike... woohooo... project almost finished !DeanO
ORIGINAL: darkside
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They have Molex connectors.
I have done three 07 bikes now with new bars and extended the wiring and although not as easy to disassemble as the deutsch connectors on the earlier twin cams they are not that hard and are easier to get out the bottom of the handlebars due to being smaller.
Bugger if I would have a dealer do it for me........
Everytime they have done internal wiring on peoples bikes they always seem to blow fuses at odd moments and for no reason then claim it is normal.
[IMG]local://upfiles/24314/E013B5D11A4B4A7BAF3CEA32705B04A6.jpg[/IMG]
[IMG]local://upfiles/24314/44CA22E2E7AC45B5A0D198C17193A4BE.jpg[/IMG]
Elite HDF Member
Joined: May 2006
Posts: 3,927
Likes: 5
From: Midwest
RE: Wiring inside your handlebars
You can always splice the extra wire into the middle (the part that will be unseen inside the bars) leaving both ends intact. If you do, make sure you stagger your splices along the wire so that you don't have a big gob of splices all in one spot making the wiring hard to pull through. And ditto on the part about smoothing the edges of the holes. Wire bending across a sharp edge will give you many hours of misery.
Thread Starter
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Novice
Joined: Aug 2007
Posts: 24
Likes: 1
From:
RE: Wiring inside your handlebars
Hey thanks guys! Lots of food for thought! The bars I got are just some Chromewerks (sp?) bars - dunno what they're called but they're a bit straighter and shorter than stock which I prefer. Not quite drag bars but they keep your hands straighter than the buckhorns do. So I will have a bit of slack to play with!
Deano it's a '98 Fatboy. I'm changing bars at the same time as replacing the front end with an SJP F-Glide. It's my "poor-man's Exile"!
Deano it's a '98 Fatboy. I'm changing bars at the same time as replacing the front end with an SJP F-Glide. It's my "poor-man's Exile"!
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Stellar HDF Member
Joined: Nov 2005
Posts: 2,272
Likes: 10
From: Orange VA
RE: Wiring inside your handlebars
If you do go the cut and solder route I recommend staggering the cuts/solders. Unless you are a super-solderer, lining all the cuts up together will end up with a huge lump of solder, wire, and shrink tube. It'll look like a Boa that just ate a basketball and be a PITA to pull through anything. If you stagger the cuts by an inch or so you end up with a more uniform size cluster of wires which makes it much easier to pull through.
A feeder string is helpful in pulling the wires through the bars too. A quick and easy way to get string through is to tape off the opposite end of the bars. Start the string into the wiring hole while holding on to the other end of the string. Use an air compressor to blow air into the grip end of the bars. It will push the string down the bars until it pops out the bottom opening. Attach to your wires to the string and pull them through. Repeat for other side.
Oh yeah. We expect pics of the finished product. Good luck.
A feeder string is helpful in pulling the wires through the bars too. A quick and easy way to get string through is to tape off the opposite end of the bars. Start the string into the wiring hole while holding on to the other end of the string. Use an air compressor to blow air into the grip end of the bars. It will push the string down the bars until it pops out the bottom opening. Attach to your wires to the string and pull them through. Repeat for other side.
Oh yeah. We expect pics of the finished product. Good luck.
