Wiring inside your handlebars
Road Captain
Joined: Oct 2006
Posts: 678
Likes: 2
From: Illinois_non-chicago
RE: Wiring inside your handlebars
ORIGINAL: BG Weasel
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.
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.
another tip...... take a piece of fishing line or thread and tie a small nut on it and drop the nut through one of the holes and move the bars around to get the nut to come out the other hole. then tape and/or tie a thicker string on and pull that through and use that to pull in your wires. you can also rub some soap on you wires to help them slide in easier. just take your time a scuffed wire my not rear it's ugly head until your miles down the road......
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Novice
Joined: Aug 2007
Posts: 24
Likes: 1
From:
RE: Wiring inside your handlebars
Wow you guys are great! OK - so I looked at the page on how to pull a Deutsch plug apart and that was it. My bars are now done. To look at it you wouldn't guess how easily the plug would come apart.
I do have some electrical experience - before I got into pulling expensive bikes into little pieces I taught myself how to build tube guitar amps. You gotta love the internet! Thanks heaps guys - you have made a seemingly tricky job very simple.
I do have some electrical experience - before I got into pulling expensive bikes into little pieces I taught myself how to build tube guitar amps. You gotta love the internet! Thanks heaps guys - you have made a seemingly tricky job very simple.
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Novice
Joined: Aug 2007
Posts: 24
Likes: 1
From:
RE: Wiring inside your handlebars
I will be proud to show pics once it's done! Actually I have tried to upload some pics of my bike before but I'm not too good with pic posting - it never seems to work!
I am loving how the bike is looking so far though. I can't afford an Exile so I'm "Exiling" my bike. All the metal is now satin finished and the SJP front end is just amazing. I still have some wiring to do and have to get some more spacers for the front wheel and fender. I already have a Mikuni carb on it and have a Dynatek ignition system on the way. I would love to show it off, but have to (A) become more computer savvy and (B) wait til it's all done.
I am loving how the bike is looking so far though. I can't afford an Exile so I'm "Exiling" my bike. All the metal is now satin finished and the SJP front end is just amazing. I still have some wiring to do and have to get some more spacers for the front wheel and fender. I already have a Mikuni carb on it and have a Dynatek ignition system on the way. I would love to show it off, but have to (A) become more computer savvy and (B) wait til it's all done.
Cruiser
Joined: Jul 2007
Posts: 138
Likes: 0
From:
RE: Wiring inside your handlebars
Hey scotty3,just read your useful info about the Molex connectors,planning on changing my bars on my 07 Train soon do I need to get hold of that special tool shown in the diagrams you've posted? any idea of the part number?
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: hogster1961
Hey scotty3,just read your useful info about the Molex connectors,planning on changing my bars on my 07 Train soon do I need to get hold of that special tool shown in the diagrams you've posted? any idea of the part number?
Hey scotty3,just read your useful info about the Molex connectors,planning on changing my bars on my 07 Train soon do I need to get hold of that special tool shown in the diagrams you've posted? any idea of the part number?
Knowing I would be doing more than 1 bike and figuring if I broke any of the connectors it would end up costong me more than the special tool is worth to get it fixed I just said bugger it and bought one.
Part Number is HD-48114 and I got mine from John at Zanotti's HD
Scotty
Cruiser
Joined: Jul 2007
Posts: 138
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From:
RE: Wiring inside your handlebars
Cheers Bud,yeah always pays to use the right kit if it helps,got a bunch of stuff on order from a dealer in the U.S,will add it to my order,do you remember how much it cost at all?
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: hogster1961
Cheers Bud,yeah always pays to use the right kit if it helps,got a bunch of stuff on order from a dealer in the U.S,will add it to my order,do you remember how much it cost at all?
Cheers Bud,yeah always pays to use the right kit if it helps,got a bunch of stuff on order from a dealer in the U.S,will add it to my order,do you remember how much it cost at all?
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