Internal wiring....
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Road Warrior
Joined: Jan 2008
Posts: 1,351
Likes: 4
From: OKC
Internal wiring....
I am wanting to run my wires internally on my biltwell frisco bars on my Nightster. How would I go about it? Where do I disconnect? This may be a dumb question, but I don't usually like messing with wires but I am wanting to do this myself.
Thanks
Thanks
Road Warrior
Joined: Apr 2006
Posts: 1,275
Likes: 0
From: southern new jersey
the disconect should be under the tank atleast it was on mine,when i did my bars i ran the wires internal and had to re-splice all of the deutsch connectors..its not all that bad,just take your time
Tourer
Joined: Oct 2008
Posts: 260
Likes: 0
From: St.Louis,Mo.
motordrum,I think it would be easier if you were to cut the wires run them thru the inside of your bars and out the bottom then solder them back together and use shrink wrap on each wire.
If you were to disconnect were they plug into the plug under the gas tank I think the plugs are to big to go thru the holes in the handle bars.I am going to run the wires thru my drag bars I am putting on my Nightster.
If you were to disconnect were they plug into the plug under the gas tank I think the plugs are to big to go thru the holes in the handle bars.I am going to run the wires thru my drag bars I am putting on my Nightster.
Road Warrior
Joined: Apr 2006
Posts: 1,275
Likes: 0
From: southern new jersey
motordrum,I think it would be easier if you were to cut the wires run them thru the inside of your bars and out the bottom then solder them back together and use shrink wrap on each wire.
If you were to disconnect were they plug into the plug under the gas tank I think the plugs are to big to go thru the holes in the handle bars.I am going to run the wires thru my drag bars I am putting on my Nightster.
If you were to disconnect were they plug into the plug under the gas tank I think the plugs are to big to go thru the holes in the handle bars.I am going to run the wires thru my drag bars I am putting on my Nightster.
if you unplug from the harness under the tank you can cut them there and get the new pin(deutshe) connectors to replace the ones you cut off at your local stealer..if you need to extend the wires i think you can get a harness from the dealer to extend the existing wires
Cruiser
Joined: Jul 2008
Posts: 118
Likes: 0
From: Greenville NC
I just completed this a few hours ago, there are several steps but if you take it one at a time it is easy.
1) remove controls and grips from stock bars, along with attached wire harness.
2) remove the connectors from the wire harness (the end that connects to the bikes main wire harness) this can be tricky. Looking at the connectors at the end where the wires go into the connector there are 2 holes between all of the wires, use needle nose pliers to pull the plastic piece out a little, it will snap out about 1/4 inch but will stay in the connector body. Then look at the other end of the connector (where the pins come out) above each pin is a small hole, use a push pin about the size of a paper clip and insert into the hole until it clicks, you can then pull that wire out, repeat until they are all out. Remember to draw a diagram so you put them back in the correct order.
3) measure how much more length you need by mocking up bars and measuring with spare wire/string etc.
4) Now you need to extend your wires by cutting and soldering in extensions, make sure to stager your joints to avoid a lump of connections and to heat shrink all connections and then heat shrink the entire harness again to avoid chaffing.
5) if your bars aren't pre-drilled drill the needed holes.
6) Thread fishing line or light string though your bars, then attach to heavier string and pull through, then use electrical tape and join the string and your new harness and pull through the bars.
7) Insert wires into connectors using your previous diagram, then snap the plate on the reverse side back down to lock in the wires.
8) Mount controls on bars, bars on bike, plug in wires and RIDE!!!
Hope this helps, let me know if Im not making sense any where.
David
1) remove controls and grips from stock bars, along with attached wire harness.
2) remove the connectors from the wire harness (the end that connects to the bikes main wire harness) this can be tricky. Looking at the connectors at the end where the wires go into the connector there are 2 holes between all of the wires, use needle nose pliers to pull the plastic piece out a little, it will snap out about 1/4 inch but will stay in the connector body. Then look at the other end of the connector (where the pins come out) above each pin is a small hole, use a push pin about the size of a paper clip and insert into the hole until it clicks, you can then pull that wire out, repeat until they are all out. Remember to draw a diagram so you put them back in the correct order.
3) measure how much more length you need by mocking up bars and measuring with spare wire/string etc.
4) Now you need to extend your wires by cutting and soldering in extensions, make sure to stager your joints to avoid a lump of connections and to heat shrink all connections and then heat shrink the entire harness again to avoid chaffing.
5) if your bars aren't pre-drilled drill the needed holes.
6) Thread fishing line or light string though your bars, then attach to heavier string and pull through, then use electrical tape and join the string and your new harness and pull through the bars.
7) Insert wires into connectors using your previous diagram, then snap the plate on the reverse side back down to lock in the wires.
8) Mount controls on bars, bars on bike, plug in wires and RIDE!!!
Hope this helps, let me know if Im not making sense any where.
David
Tourer
Joined: Oct 2008
Posts: 260
Likes: 0
From: St.Louis,Mo.
I just completed this a few hours ago, there are several steps but if you take it one at a time it is easy.
1) remove controls and grips from stock bars, along with attached wire harness.
2) remove the connectors from the wire harness (the end that connects to the bikes main wire harness) this can be tricky. Looking at the connectors at the end where the wires go into the connector there are 2 holes between all of the wires, use needle nose pliers to pull the plastic piece out a little, it will snap out about 1/4 inch but will stay in the connector body. Then look at the other end of the connector (where the pins come out) above each pin is a small hole, use a push pin about the size of a paper clip and insert into the hole until it clicks, you can then pull that wire out, repeat until they are all out. Remember to draw a diagram so you put them back in the correct order.
3) measure how much more length you need by mocking up bars and measuring with spare wire/string etc.
4) Now you need to extend your wires by cutting and soldering in extensions, make sure to stager your joints to avoid a lump of connections and to heat shrink all connections and then heat shrink the entire harness again to avoid chaffing.
5) if your bars aren't pre-drilled drill the needed holes.
6) Thread fishing line or light string though your bars, then attach to heavier string and pull through, then use electrical tape and join the string and your new harness and pull through the bars.
7) Insert wires into connectors using your previous diagram, then snap the plate on the reverse side back down to lock in the wires.
8) Mount controls on bars, bars on bike, plug in wires and RIDE!!!
Hope this helps, let me know if Im not making sense any where.
David
1) remove controls and grips from stock bars, along with attached wire harness.
2) remove the connectors from the wire harness (the end that connects to the bikes main wire harness) this can be tricky. Looking at the connectors at the end where the wires go into the connector there are 2 holes between all of the wires, use needle nose pliers to pull the plastic piece out a little, it will snap out about 1/4 inch but will stay in the connector body. Then look at the other end of the connector (where the pins come out) above each pin is a small hole, use a push pin about the size of a paper clip and insert into the hole until it clicks, you can then pull that wire out, repeat until they are all out. Remember to draw a diagram so you put them back in the correct order.
3) measure how much more length you need by mocking up bars and measuring with spare wire/string etc.
4) Now you need to extend your wires by cutting and soldering in extensions, make sure to stager your joints to avoid a lump of connections and to heat shrink all connections and then heat shrink the entire harness again to avoid chaffing.
5) if your bars aren't pre-drilled drill the needed holes.
6) Thread fishing line or light string though your bars, then attach to heavier string and pull through, then use electrical tape and join the string and your new harness and pull through the bars.
7) Insert wires into connectors using your previous diagram, then snap the plate on the reverse side back down to lock in the wires.
8) Mount controls on bars, bars on bike, plug in wires and RIDE!!!
Hope this helps, let me know if Im not making sense any where.
David
JT.
Cruiser
Joined: Jul 2008
Posts: 118
Likes: 0
From: Greenville NC
Im glad someone could understand my rambling on!
David
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