I tried to find tips on pulling the wires through internally wired handlbars but there aren't a lot of details available on the wiring part of the job. These are Khromewerks Fat Bagger Apes 12". The problem seems to be the bend at the bottom just before the clamp. The pins make a sizeable and stiff spot at the end of the protective sleeve.

I've taped them all together around the pull wire, and used vaseline, but so far just getting frustrated. What makes a good pull wire?

Anyone got a favorite way to do this that works without too much agravation? I've read to get smaller heat shrink tube - what size would that be. I hate to cut off the sleeve that's on there now and not be able to find the replacement tube.

So far the removal has gone well... just need to get the wires and switches on the new bars. Thanks in advance.

 

I have not done this but I plan on it and was going to use a guitar string when I do it, small and strong!
Here's a link I found that I plan on following, I believe the guy has a "contact me" link if you have questions. Let us know what you use and how it works out.
http://www.kenandjudy.us/Motorcycles...new_page_1.htm

 

Right side can be a pain on TBW bikes. I have cut the green connector out and sodered the wires to make the bundle smaller. Harley sells a replacement TBW that doesn't have the green connector. Radio Shack should have some heat shrink to make the bundles smaller. Left side usually isn't much of a problem. Don't use a lot of tape around the pins. I use MIG wire with a loop on the end and taped just behind the pins to pull the bundles thru.

 

Got the left side in no problem. Pulled the TBW/Right side wires all the way through together to poing where pins are out at the bottom, but too tight to get TBW all the way into the grip end of the handlebar.

Anyone done this who can share a secret?? Do I need to cut the sheath off one or both sets of wires and put heat shrink tube on to make bundle(s) smaller? I did NOT get the replacement TBW that comes witout the green plug.

But, I got it all in there one time as is, just couldn't get everything all the way in!

Would appreciate any advice.

 

I used picture hanging wire and electrical conduit wire pulling lube.

 

Cut the original sleeve on your controls and buy some heat shrink wire rap divided the wires in two sections if I can remember should be 6 wires on either side take second set of 6 wire and tape them and inch lower this should help going around that bend.

 

I assume you've seen this
https://www.hdforums.com/forum/touri...ml#post8005899

 

Green connector is probably hanging things up in the top bend. I pull off the factory sheath and heat shrink the switch wiring and TBW wiring in seperate bundles. Tape or heat shrink the TBW connector so it can't come apart.

 

Put all wires in Heat shrink, control wires in one rap and the TBW wires in another, than pull all of them together. I had trouble with the trottle sensor going into the bars all the way on my Street Glide, after I got all the wires thru the hole in the bottom of the bars I pulled the TBW wires only and pushed the control at the same time, becareful not to break the sensor. Make sure the sensor is aimed towards the correct notchs so you don't have to spin the sensor to line it up. I did buy the CVO TBW sensor for my Roadie, but that was a waste of money, the wires were not any longer and the heated grip wires are not long enough to make it out of the bars (I will never use them anyways). My Street Glide I cut the green plug off and soldered.

 

stagger the wires or pull them a couple at a time.