Help with running wires internally on handlebars
Thread Starter
|
Road Captain
Joined: Nov 2007
Posts: 731
Likes: 2
From: Montreal Quebec Canada
Help with running wires internally on handlebars
Looking to run my handlebar wires internally this weekend. Read somewhere i need a removal tool from Harley to get the wires out of the connectors. I know you guys have tricks to do it. Any help is appreciated. Thanks
Tourer
Joined: May 2007
Posts: 319
Likes: 1
From: Great State of Texas
Go to brcustombars.com there is some vid's showing you how to run the wires. If you just want to remove the pins from the connector straighten a paper clip out and use it in the hole adjacent to the wire you wish to remove. Insert the end and pull on the wire.
Road Captain
Joined: Jul 2009
Posts: 545
Likes: 1
From: Miami, Florida
If you just want to remove the pins from the connector straighten a paper clip out and use it in the hole adjacent to the wire you wish
May our Moderator Rest in Peace
Joined: Sep 2006
Posts: 11,386
Likes: 35
From: Rochester, NY
First, get a manual. It has the instructions for how to pull all the connectors apart without damaging them and a hell of alot of other good stuff.
But in the mean time check out this posting that Mud put up on how they work.
https://www.hdforums.com/forum/showt...04#post3061604
Good Luck, and ride safe.
But in the mean time check out this posting that Mud put up on how they work.
https://www.hdforums.com/forum/showt...04#post3061604
Good Luck, and ride safe.
Road Master
Joined: Oct 2009
Posts: 1,178
Likes: 6
From: N.C.
I did mine about 2 months ago. If you did like me and used the stock handlebars that ARE NOT drilled, be ready to dull an air grinder bit and drill bit or two.
Also smooth out the rough edges, and when you think its smooth hit it again to make sure its smooth and no chaffed wires will occour on down the road. Pull the tank up (Does not need to be pulled all the way off) to gain access to the plugs on the left and right.You will need to pull the fuel line croosover hose lose, so drain the tank outside the shop ,trust me on this one. This will give you the height you need to lift the tank once you pull the front bolt and the rear bolt. Also remove the speedo console and unplug the wires from it to let you lift the tank high enough. Its easy to pull the wires out of the plastic plug itself coming from the handlebars, Just be patient and use common sense. The plugs are located about mid way back of the tank under the tank and clipped to the frame. Here are some pics below from about 2 months ago after I finished.
Also smooth out the rough edges, and when you think its smooth hit it again to make sure its smooth and no chaffed wires will occour on down the road. Pull the tank up (Does not need to be pulled all the way off) to gain access to the plugs on the left and right.You will need to pull the fuel line croosover hose lose, so drain the tank outside the shop ,trust me on this one. This will give you the height you need to lift the tank once you pull the front bolt and the rear bolt. Also remove the speedo console and unplug the wires from it to let you lift the tank high enough. Its easy to pull the wires out of the plastic plug itself coming from the handlebars, Just be patient and use common sense. The plugs are located about mid way back of the tank under the tank and clipped to the frame. Here are some pics below from about 2 months ago after I finished.
Last edited by Rockyriver; Dec 15, 2009 at 08:38 AM.
Seasoned HDF Member
Joined: Apr 2008
Posts: 5,699
Likes: 15
From: Qualicum Beach, B.C. CAN
Reading about it is harder than actually removing the pins.
Tiny screwdriver and gentle hands and you got it.
Tiny screwdriver and gentle hands and you got it.
Trending Topics
Road Master
Joined: Apr 2009
Posts: 953
Likes: 0
From: SOUTH-ALABAMA
question pertaining to this. I am running my wires tonight. instead of attacking this by removing the pins, I am going to hit the wires somewhere in their trip up with some extensions. Im at work, dont have my manual, but have access to these nice but connectors / heat shrink tubes. what gauge are my wires coming from the controls? (07 FXST) Can I - Lift tank, un clip harness, cut wires just forward of harness, take cut ends up top and run the down the bars towards the tree, then button everything up down there??
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Elite HDF Member
Joined: Feb 2006
Posts: 3,818
Likes: 2
From: Twin Cities
twist call me later when ya get home i will explain everything to ya its easier then ya think...........if you went with 14s ya cant cut the wires and feed em through they wont make it to the bottom of the bars...........if you off set the cuts and put the extenders on then you can get away with cutting, all depends on wut extend kit you got
Road Master
Joined: Apr 2009
Posts: 953
Likes: 0
From: SOUTH-ALABAMA
twist call me later when ya get home i will explain everything to ya its easier then ya think...........if you went with 14s ya cant cut the wires and feed em through they wont make it to the bottom of the bars...........if you off set the cuts and put the extenders on then you can get away with cutting, all depends on wut extend kit you got