I used dish soap on my bars worked out pretty good.

 

I used Windex as a lube. I actually got the idea from the Harley service manual.

Anyway, you should look for that part that Dawg posted. It will make things easier.

Having a CVO, my was with that part stock. I ran my TBW wires first, but didn't seat them all the way into the bar. Maybe left about half of the sensor exposed.

After that was done, I ran my controls wiring through. It was really a pain, but this was the best way I found to do it. Once the controls were nearly fully ran, I pull them both through together, seating them all the way.

Good luck. The best tool for this job is patience.

 

try doing the two sets together with a little baby powder....

 

Oh, by the way I did mine two years ago and I remembered that I also taped over the connectors and then fed the two sets of harness (wire) through the bar.

 

Thanks everyone for the ideas (except that Misery Tigers fan that snuck in ....so, when you say stagger the ends, do you heat shrink them at all, or pull through without heat shrink? i tried to stagger at one point and got the first few through, but by the time the next few were ready, the wires were bunched up at the top of the bars and wouldn't pull through anymore. Am i supposed to disconnect from the switch end too?

I have 10" bars, so I didn't do any extension based on what I've ready on the other threads.

Thanks again...i'm thinking about going back at it to try again tonight, but maybe another night away getting mentally prepared would better.

Thanks again guys.
sv

 

I can't speak to pulling them past the green clip on the TBW sensor, but I would try taping all the pins together too. I also found that pulling the wires was a misnomer. Actually, push from the grip end, then pull, then push, then pull, and so on.

I think that the TBW clip is what's holding you up. Lots of folks have removed it entirely and soldered in extensions.

 

by staggering the wires I mean out of the 16 wires, break them out into groups of 4 and attach them a inch or so apart on your pull string/chain so they dont get bunched up when making the bends. tape the tips of each of the 4 wires to the pull string so they dont get caught making the turns and break/bend. Go get some of the wire pull lube, it will get the job done fast (I tried windex and WD 40 and it worked "ok" cable lube worked like a charm) Fish eye is correct, push more than pull and use elect tape to attach to wires to pull string (duct tape is too thick and does no hold as well as tight elect tape.)

 

I too installed the 10" MBB and did not use extensions. I followed Yaffee's instructions (which I can email to you). I heat shrinked all of them.

dave

 

I cut out the green plug and soldered the wires (after the plug disintegrated while pulling). I used heat shrink to bundle the wires. Be careful that you shrink it but don't get so tight that it wrinkles. I used conduit lube and weed-eater string for a pull string. I was very liberal with the lube, it dripped out for a couple of days. Doesn't hurt anything though. I pulled the wires in staggered bundles. I think there were three bungles. I staggered then about 2" apart. My wife and I worked them through using a push pull method. The extra set of hands were very helpful. It took about 30 mins if you don't count the time I had to start over because I broke that damn green plug. That's why I always recommend the SE TBW.

 

I kept the stock TBW plug, started the switch wires and the TBW so they pull together and seat at the same time, no problems. The electrical pulling lube is a life saver. Haven't had to buy any(friends an electrician) but I use it on all the internal wiring I do.