Running wires through bars
Grand HDF Member
Joined: Sep 2007
Posts: 4,109
Likes: 37
From: Boise Idaho
I have done this many times, the only real secrets are, make certian the holes in both ends of the bar are large enough for the amount of wires your are going to drag throw them and make certian you debured the holes, when you make up the loom don't make all the wires the same length, you want to have several differant length wires so you aren't trying to drag the entire thickness through at once and make certian you use plenty of lube, I use WD-40 and spray it down the inside of the bars and spray down the harness and don't use string use mechanics wire because some times you have to pull pretty hard to get it throw, I can't imagine string working very well.
Also make certian you solder and shrink wrap everything this is not a job for butt connectors!!
Also make certian you solder and shrink wrap everything this is not a job for butt connectors!!
Last edited by jag1886; Dec 30, 2008 at 05:51 PM.
Road Master
Joined: Sep 2005
Posts: 1,190
Likes: 1
From:
First of all...if you're going to go through the trouble of doing this, ditch the stock bars!
I've done this with a set of Wild1 Chubby bars and it's not a bad job at all. I even had to extend my wiring..just took my time and soldered everything. It takes patience but is not difficult. I think it may be tougher on a stock diameter bar though..it was fairly tight on the thicker chubby bars, the stockers I can see being a pain. Spend the 150 on a set of bars, do the internal wiring and you'll be stylin'
I've done this with a set of Wild1 Chubby bars and it's not a bad job at all. I even had to extend my wiring..just took my time and soldered everything. It takes patience but is not difficult. I think it may be tougher on a stock diameter bar though..it was fairly tight on the thicker chubby bars, the stockers I can see being a pain. Spend the 150 on a set of bars, do the internal wiring and you'll be stylin'
Elite HDF Member
Joined: Sep 2005
Posts: 3,947
Likes: 5
From: Ontario, Canada
I have the Wild one 575's on my bike as well and although I agree with the above post, you don't need to extend the wires. Just disasemble the plug and find a different route inside the fairing and you'll be good to go.
Advanced
Joined: Feb 2007
Posts: 75
Likes: 0
From: Sedona, Arizona
Did this on my 07 RK, which has stock HD reduced reach bars. My bike has cruise control which means lots of wires. Several ways to pull the wires through the bars, talcum powder, tape, etc. The hard part for me was cutting the wires in the area of the headlight, which I did to gain some extra length and to simplify the operation. (I didn't want to disconnect the wires from the switches.) I believe an aftermarket shop now has an extension kit for this(Kurykayn?). Soldering is not difficult, I made a simple jig (to hold the wires while soldering.) With shrink tubing the job can be done simply enough. I also used auto connectors when I put in the wire extension in case I wanted to switch bars in the future. All wires are color coded and easy enough to cut, put in extensions and re-connect. Just take your time.
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Powertrip240
2014-2024 Touring Models
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Mar 16, 2016 07:38 PM
14, bars, cyclesmith, grips, handlebars, heated, pulling, route, run, softail, stock, streetglide, tips, wires, wiring
