Changing bars with internal wiring???
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Tourer
Joined: Nov 2007
Posts: 276
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RE: Changing bars with internal wiring???
Thanks guys.I am a mechanical contracor and grew up in my dads electrical and mechanical contracting business.Never had a bike in the shop in 35 years.When I was 12 and blew up my mini bike I told my dad we need to take it to the shop.He looked at me like I was crazy,so I tore down the Briggs & Stratton.Now I'm getting lazy and would like to just drop it off and get it done.However 300 bucks labor is rediculous.
Outstanding HDF Member
Joined: Sep 2007
Posts: 2,782
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From: NC
RE: Changing bars with internal wiring???
i brought my 16" apes to my indy after i dicked around for over 2 hours....he did them in 1/2 hr, the trick for him is to use an old speedo cable as a snake
oh and this was for the cop wires too...i foget but i think 10 on one side 12 on the other, i know more than stock
oh and this was for the cop wires too...i foget but i think 10 on one side 12 on the other, i know more than stock
Banned
Joined: Aug 2006
Posts: 1,433
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From: Denver Colorado
RE: Changing bars with internal wiring???
This post pretty much narrows it down...nice job Gunner...and NICE bars! 
ORIGINAL: gunner065
As said above, it's not hard just time consuming and tedious. I used a shop vac to bring a piece of heavy strength line through the bars and taped it really good to the wiring, paying special attention that the connectors were covered so you don't haul any of the ends off. I found that the stock wire protective sheath was harder going back through. I cut mine off and got some shrink tubing and covered the wiring with that, plus a little silicone to make it slide easier. I removed the tank and prior to taking the connectors apart, I took pictures as well as drew diagrams of the correct setup. Taking the pins out I used a paper clip and it was a bitch on the first one, but after when you get the knack of it, they come apart really easy. Take your time and get a manual. Good luck.
As said above, it's not hard just time consuming and tedious. I used a shop vac to bring a piece of heavy strength line through the bars and taped it really good to the wiring, paying special attention that the connectors were covered so you don't haul any of the ends off. I found that the stock wire protective sheath was harder going back through. I cut mine off and got some shrink tubing and covered the wiring with that, plus a little silicone to make it slide easier. I removed the tank and prior to taking the connectors apart, I took pictures as well as drew diagrams of the correct setup. Taking the pins out I used a paper clip and it was a bitch on the first one, but after when you get the knack of it, they come apart really easy. Take your time and get a manual. Good luck.
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