Handlebar Internal Wiring help???
Novice
Joined: Jul 2008
Posts: 21
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From: Rancho Santa Margarita, CA
Might be tough to run all your wiring inside those bars...
As far as running the wires internally I understand your heads up about the 1/2" clearance inside the bar at the bend but the only wire going through that bend is the throttle wires. The other wires would enter the bars in the hole that I drill which would be in the end of the dimple in the bar. I already have the heritage style bars so I have nothing to loose by drilling them and trying to run the wire internally. The money is not a factor for my trying my heritage bars, I just have not seen any other bars that I liked the hand grip position.
Last edited by OC2CO Rider; Feb 22, 2010 at 04:56 PM. Reason: Correction
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Cruiser
Joined: May 2009
Posts: 217
Likes: 10
From: Monroe, Ohio
Well I love a challenge. I got the bars from Harley and they are for my 09 with fbw so I HAVE to run that internal. Worst case scenario is that after I drill the holes for the other wires they are too tight and I just run them on the outside. No one would ever know the hole has been drilled because the wires would cover the holes.
I will keep you posted and I might even take some pics as I go along.
I will keep you posted and I might even take some pics as I go along.
Last edited by scuba1954; Feb 24, 2010 at 11:44 AM. Reason: new photo
Seasoned HDF Member
Joined: Jan 2006
Posts: 11,471
Likes: 2,998
From: Charleston, SC
Those are 1" bars. I've seen it done on 7/8" bars with factory bends. It's not impossible. Get the holes drilled right, take your time and you won't have any problems. Yes, drilling them will weaken the bars. Just don't go Gorilla gripping them and you won't bend them by accident.
That said, after running wires down 15 different sets of bars on just as many bikes, I'm done doing it. For my latest bike (2010 RG) I used blacked out Heritage bars and ran the wires on the outside like stock....the End...Done...I'm riding.
Good luck though. It's kinda fun running them internally the first or 10th time you do it.
lp
That said, after running wires down 15 different sets of bars on just as many bikes, I'm done doing it. For my latest bike (2010 RG) I used blacked out Heritage bars and ran the wires on the outside like stock....the End...Done...I'm riding.
Good luck though. It's kinda fun running them internally the first or 10th time you do it.
lp
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Cruiser
Joined: May 2009
Posts: 217
Likes: 10
From: Monroe, Ohio
I really appreciate your concerns. Since these bars came from Harley for my bike they are made to fit my FBW setup. I will see how hard it is to pull the throttle wires first and if that is an easy pull then I will drill the bars for the rest of the control wires. According to the shop manual there is only 6 wires for control on each side.
I work with a guy who has done this on his RK already that is why I know where to drill the hole. He said his hole only needed to be 3/8" and the bars integrity do not seem to have been comprimised at all. It still cold here in OHIO so after it warms up some then I will put the bars on. I have a new twist grip sensor and wire extension kit that harley shows I will need for the internal wires. They should be here next week. After I get the new twist grip sensor and see if it fishes through the bars easy then I will drill the holes. I will keep you guys informed.
I work with a guy who has done this on his RK already that is why I know where to drill the hole. He said his hole only needed to be 3/8" and the bars integrity do not seem to have been comprimised at all. It still cold here in OHIO so after it warms up some then I will put the bars on. I have a new twist grip sensor and wire extension kit that harley shows I will need for the internal wires. They should be here next week. After I get the new twist grip sensor and see if it fishes through the bars easy then I will drill the holes. I will keep you guys informed.
Road Warrior
Joined: Sep 2005
Posts: 1,942
Likes: 7
From: guntersville, al
all you will need is the correct bars. the throttle cable will disconnect near center and come out easily. pull the sensor out of the bars far enough to disconnect the wiring. of course you will have to disconnect inside the nacelle first. when removing the spear on the nacelle to remove the bar clamp cover, don't take the rear nut all the way off so you don't drop it inside. the nacelle is slotted so the spear is easily removable.
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Cruiser
Joined: May 2009
Posts: 217
Likes: 10
From: Monroe, Ohio
Well after taking my time I got the cables all run inside the Heritage bars and installed on my bike. I had originally drilled a 1/2" hole in end of the dimple closest to the center of the bars on each side. That hole had to be elongated to about 3/4" then I was able to pull the cables through after I used some pulling lube to make them slippery. I was able to leave the factory black protective sleeve on the cables to make sure that they were protected where they entered the bars. I needed to buy the 70198-07 HD wire extension kit so the wires reached inside the headlight bucket. I ended up using the original twist grip sensor. When I pulled it inside my new bars I used the pulling lube again. The only pics that I had taken was the when I had drilled the first set of holes in the dimples. I did not take any photos after I elongated them. The photo that I have added below shows the first hole that I drilled and then I used a red marker to show how much more I had to enlarge the hole.
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