I did my wife's Z-bars what a pain!!! I did it the first time, then during Bike Week she got hit, f'd up the bars!!! And had to do it again!!! But as said earlier, a little vaseline and patients. I had to use a nut and string to feed throught the bars. Mig wire wouldn't work with the Z's, I had to tripple the string to pull it. After walking away one night, the next night went easier.
Jody

 

WD 40 on electrical wiring is a very bad idea. It will break down the insulation over time and you will have a big mess on your hands. WD 40 is about 70% solvent and is also flammable. You are better off using a liquid soap or there is actually a wire pulling compound you should use.

 

You can get Clear Glide wire lubricant made by Ideal from Home Depot for about 5 bucks. I had trouble with the green TBW connector and ended up cutting it out and soldering and using heat shrink tube on the wires.

 

I just did a Sporty today, right side controls, turn signal and LED fuel gauge in 1" bars, everything slid right through, no lube needed.

The key is in the hole prep. Do not just use the holes that com in predrilled bars, even IF they are big enough they are punched and have sharp edges inside. I use a inline die grinder with a tapered tree bit and work the inside until its nice and smooth and I can run my finger inside without getting snagged.

 

Or in other words, make the holes like Wild 1's come from the factory....