Pulling wires

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Apr 23, 2011 | 07:17 AM

PFIRE

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6th Gear

Joined: Sep 2010

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From: Ohio

Pulling wires

I'm installing my new 16" apes and having a hell of a time pulling the wiring harness with extentions. I have them pulled thru to the bottom but can't make the to bend up thru the bottom hole. Any ideas?

Apr 23, 2011 | 07:21 AM

DR. V-TWIN

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Joined: Jan 2009

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From: Los Angeles, CA

WD-40, baby powder, etc. I always tie whatever I am using to pull the wires onto the wires and then wrap a bunch of electrical tape around it as close to the end of the wires as i can without breaking the pins off the end of the wires. You could also put a tad bit of grease aroudn teh hole at the bottom and that MIGHT make it slide through a little easier.

Drew

Apr 23, 2011 | 08:01 AM

Roadie09

Road Warrior

Joined: Jun 2008

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From: Deep South Texas

You did not mention which bars you were using, but some bars have the exit hole on the small side. I was forced to enlarge the hole on a previous project. I think some bars are universal fit (which basically means they don't fit anything) and need a little modification to allow all the wires from a bagger to come out.

I have also had good luck coating the wires/loom with K-Y/Baby Oil Jel, don't laugh it works. Plus, when you are done you will be ready to call the old lady out to relieve the tension from jacking with the bars

Apr 23, 2011 | 08:13 AM

CrusingHarley

Cruiser

Joined: Jul 2010

Posts: 222

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From: Massachusetts

I cannot comment on the bars you are installing, but I can comment on wire pulling lubricant. Do not use WD-40, baby oil, grease, vasoline,etc, as these materials can deteriorate the insulation over time.

If you are sure the hole is big enough, then go to Home Depot or your local hardware store and purchase a bottle of wire pulling lubricant. This stuff is very slippery and will not damage the insulation of the conductors. Also when taping the wires, it may help to stagger the wire, and when taping, make sure the tape is tight and low profile. You do not want a big glob of tape.

Hope this helps.

Last edited by CrusingHarley; Apr 23, 2011 at 08:19 AM.

Apr 23, 2011 | 08:16 AM

Hydroboy35th

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Joined: Apr 2011

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From: Dublin,Ohio

I used vasoline with the push/pull method and It worked great.

Apr 23, 2011 | 08:41 AM

PFIRE

Thread Starter

6th Gear

Joined: Sep 2010

Posts: 14

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From: Ohio

I will try these today thanks alot. One other question I think I may have screwed up a couple of the pins can I get these some where I have plenty of wire I got the 12" ext. and prob only needed the 8".

Apr 23, 2011 | 11:01 AM

bagman1

Grand HDF Member

Joined: Dec 2007

Posts: 4,999

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From: Bay Area

Quote:

Originally Posted by PFIRE

If you screwed up the wire terminals you need to go to HD, they are captive parts. For about $.40-.50 per pin its not worth the problems down the road for poorly fitted wire connections if you find something that "willfit".
As mentioned wire lube is good, I used spray wet type silicone and took about 1/3 of the wire ends and folded them back and taped from the tip of the harness all the way back, this makes for a stiff harness to push/pull. Make sure it is small and no bulges, I also took some thin bailing type wire and taped it on to the loom to pull it thru, one needs to push on the loom while pulling the other end. But secure the wire along the harness so youre not pulling on the terminal ends.