Need Tip - Handlebar Wiring
Intermediate
Joined: Feb 2009
Posts: 32
Likes: 0
From: UT
I pulled the wires through using safety wire. Lowe's has twine that's made for pulling electrical. wrap the pins with black tape and make the head tapered towards the front to pull easier. You should not need lube to get the wires through.
Road Captain
Joined: Mar 2007
Posts: 572
Likes: 6
From:
Maybe this will help too. I put it together some time ago.
https://www.hdforums.com/forum/touri...e-install.html
https://www.hdforums.com/forum/touri...e-install.html
Thread Starter
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Cruiser
Joined: Jun 2010
Posts: 226
Likes: 3
From: Middle Georgia
Pulling Wire inside Handlebars
Finally gor 'r done... with a combination of ideas from the forums, the wire bundles are in! I made a trip to home improvement warehouse type store for the shriink tube but all they had were short pieces for splices (glad I didn't cut the sheath off before I went 
). None of the auto stores or Radio Shack open by this time, so I fished two pull wires into the bars and hooked on to each bundle separately. Since I had gotten all but about 8" of the TGS bundle in once before, I pulled the TGS in most of the way first, then started the switch bundle together w/TGS, pushing and at same time pulling on the pull wire. Was still a tough pull, but they are in, bars on and set. Test fired the engine just to make sure I hadn't pulled the TGS wires apart at the green connector and everything ran fine. Now just need to hook up the new platinum braid brake lines and clutch cable and get everything buttoned back up. Quite a learning experience.
Thanks a million for all the help; the Forum is great!
). None of the auto stores or Radio Shack open by this time, so I fished two pull wires into the bars and hooked on to each bundle separately. Since I had gotten all but about 8" of the TGS bundle in once before, I pulled the TGS in most of the way first, then started the switch bundle together w/TGS, pushing and at same time pulling on the pull wire. Was still a tough pull, but they are in, bars on and set. Test fired the engine just to make sure I hadn't pulled the TGS wires apart at the green connector and everything ran fine. Now just need to hook up the new platinum braid brake lines and clutch cable and get everything buttoned back up. Quite a learning experience.Thanks a million for all the help; the Forum is great!
Road Warrior
Joined: Aug 2008
Posts: 1,895
Likes: 121
From: Southern WV
I put the WO 577's (12.5) on mine and +6 on the clutch and brake worked fine.
Thread Starter
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Cruiser
Joined: Jun 2010
Posts: 226
Likes: 3
From: Middle Georgia
Length of Stock Cables/Lines
My bike is 2009 EG Classic. I'll measure the stock lines tonight and let you know. I got the clutch cable (Barnett) and brake lines from Johnny Vaughn at HD Bike parts. Told him which bars I was using and he sent what I needed. The clutch was +4 but not sure about the brake line from master cyl to junction block. What he sent was a tad long, although it wasn't too hard to hide inside the fairing.
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Stage II
Joined: Dec 2012
Posts: 2
Likes: 0
From: hernando
have a 2000 road king with factory wire set up. does any one know whick to bullet connectors do not get plugged in on the road king/ left and right side? I believew this harness is used on all touring models that year. all my accesories work after wiring new bars but when i apply either brake it blows the 15 amp acc. fuse.
Road Warrior
Joined: Feb 2010
Posts: 1,833
Likes: 111
From: Sioux Center IA
I am putting the WO578's on and found out I cannot have the electrical wires outside the bar. So when I have time I will be doing the same as you. I just figured to tape a wire to the end and push and pull the same time. It helps these bars are very wide I would think