Running wires through bars
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Tourer
Joined: Jun 2008
Posts: 275
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From: Southern MD
Running wires through bars
Has anyone routed their hand control wiring in the stock bars? If so how did you do it and was hard? Oh yeah i have an 08 SG with the TBW (would that cause a problem as well)??
Outstanding HDF Member
Joined: Aug 2008
Posts: 2,951
Likes: 6
From: Kingman, AZ
I ran wires through the Wild 1 508's on my 08 RKC and had fits, can't imagine it all fitting through the stock bars, but maybe I am wrong. Not sure I have seen anyone do that before.
Good luck! (didn't mean that sarcastically, hope it works for you)
Good luck! (didn't mean that sarcastically, hope it works for you)
Cruiser
Joined: Feb 2008
Posts: 102
Likes: 0
From: Chattanooga, TN
I did it on my 97 RK. The stainless is tough, but it can be done. I disassembled the conectors, used drills, files, and a dremel tool (cut off wheel) to make the cut. Actually, plenty of room. Routed the outboard wires thru a .375 hole made in the corner of the handlebar crimp. Never regretted it. Not sure of number of wires to support the TBW. I had 2 addtional fat wires for lights on the end of grips. Still had room. Used shrink wrap for protection where entered and exited bars.
Banned
Joined: Oct 2007
Posts: 11,436
Likes: 13
A nightmare, and a lot of grief. Now i know why people get this done by a professional. Because the job is a real pain in the a$$, sure give it a try. See how much hair you lose trying. Ive done it, but never again. You need the PATIENCE of a "SAINT". GOOD LUCK.
Last edited by hpfatboy; Dec 29, 2008 at 06:05 PM.
Cruiser
Joined: Jul 2007
Posts: 194
Likes: 1
I have run wires inside the bars first on my Wifes 02 RK and then on her 07 RK. Both, however had 07 1-1/4 inch bars. I was even able to route the wires for heated grips inside the bars as well on the 07. (that was hard).
It takes time, of course. The shop manual to verify where the wires go into the connector and lots of wire-pulling lube are necessary.
I have a 09 RK and I plan the chubby bars, intenal wiring route on it as well. I am doubtful I can use heated grips with internal wiring, however. I have been hoping for some BTDT on that.
Eric
It takes time, of course. The shop manual to verify where the wires go into the connector and lots of wire-pulling lube are necessary.
I have a 09 RK and I plan the chubby bars, intenal wiring route on it as well. I am doubtful I can use heated grips with internal wiring, however. I have been hoping for some BTDT on that.
Eric
Road Captain
Joined: Apr 2008
Posts: 715
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From: 22 miles west of South Bend
I did mine on another brand bike with Big Johnson (beach bars)1.25" bars, removed connector and extended wires and spliced the wires in stagger fashion...took some time but came out nice and really cleaned the look up...have to solder and heat shrink.
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Joined: Nov 2008
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To pull the wires thru without grief you get one of these $2 grabber tools from most hardware / tool shops. it will fit thru a 1/2" or 3/4" hole.
afterwards you will find a million uses arond the home for it
afterwards you will find a million uses arond the home for it
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Advanced
Joined: Sep 2008
Posts: 75
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From: Minnesota
I just ran the wires through a set of Yaffee Monkey Bagger Apes. That was a Pain with the +90 degree bend. I have an 08 FLHX and the TBW plus the standard wiring was a pain to get through. Had to run the wires individual threw the throttle side. Took about 4 different tries to get it all straightened out. Had to take the clip off the TBW and spliced those wires together, the clip would NOT fit no matter what we tried... the clutch side, 15 minutes total and that includes the soldering. Was able to pull the whole assembly threw. YES it does take patience, and I had a super duper Mechanical Engineer helping me.. I think we overthought a lot of it.... But, we had nothing better to do when it's -15 below.
For the guy asking about the stock bars and running internal wiring.. NO problems, just have to get past the TBW splice. We were able to pull all the wires through with the stock plastic covering. Just pull each wire from the plug, FYI, take a pic and draw up a diagram with how they went in... the pic helps, but if you draw it out you pretty much commit it to memory and it makes it a lot easier.
For the guy asking about the stock bars and running internal wiring.. NO problems, just have to get past the TBW splice. We were able to pull all the wires through with the stock plastic covering. Just pull each wire from the plug, FYI, take a pic and draw up a diagram with how they went in... the pic helps, but if you draw it out you pretty much commit it to memory and it makes it a lot easier.
Former Sponsor
Joined: Jul 2008
Posts: 461
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From: Bend, Oregon
I just put 13" Cyclesmith's on my '08 SG. They go down to 1" where they mount to the triple-tree, so it would be the same as stock bars diameter. As far as getting them through the bars.........First, take a dremel and grind down the sharp edge on the holes you pull through. They will tear the sh*t out of the wire coating! Second, take some like 14-16 gauge electrical automotive type wire and run it through, wind it around your stock wiring harness about 2-3" up it and electrical tape it good to pull it through. Third and most important, on that wad of electrical tape where you just taped the wire to the harness, smear vaseline all over it to make it slippery. If you do all these steps it will take you about 10 minutes to have them pulled. I fought for an hour and a half until I called a buddy and he told me how to do it. BTW, I had no problem even getting the TBW connector through the 1" section.
Aaron
Aaron