internal wiring on handlebars?
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Cruiser
Joined: Mar 2007
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internal wiring on handlebars?
does this look cool, or not worth the effort on a new set of bars? i think im gonna go with wild 1 rkII's. i like the way the braided cables look with chrome switch housing, just not sure about doing internal wiring. do all the cables go inside? any pics? also what will it cost to have new bars put on? thanks yyyyaaaaaalll.
4th Gear
Joined: Nov 2005
Posts: 8
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RE: internal wiring on handlebars?
I recently purchased new bars from Wild One. I asked the dealer how much to install, with wiring inside bars. They said 8 hours labor. I think the labor rates here in San Diego are around $55-$65 per hour, so you can do the math.
I ended up doing them myself. There was a total of around 13 or 14 wires that had to be spliced, and soldered back together. Just the process of internal wiring took me around 4-5 hours. Of course, I had never done it before, and took my time.
I ended up doing them myself. There was a total of around 13 or 14 wires that had to be spliced, and soldered back together. Just the process of internal wiring took me around 4-5 hours. Of course, I had never done it before, and took my time.
Banned
Joined: Jan 2006
Posts: 17,265
Likes: 21
From: Los Angeles, CA
RE: internal wiring on handlebars?
IF you are going to change the bars you might as well put the wires inside the bars. The throttle cables and brake line stay outside of the bars. It is expensive at the stealer to have it done. You can do it.
Seasoned HDF Member
Joined: Dec 2005
Posts: 5,449
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RE: internal wiring on handlebars?
The braided throttle, brake, and clutch do not go inside the bars. Only the black loom of electrical wiring does. Your post wasn't clear if you understood this or not. I apologize if you already knew this. (EDIT - Looks like all above me were typing the same thing at the same time)
A dealer is probably going to charge you at least 3 hours labor. They will probably claim they need to extend the wiring. Don't let them convince you of this, they don't. They also may claim that the cruise control wires make the loom to big, it doesn't. Do you have heated grips? If so, that could be a problem. I've done it on my old RKC (which had RKII's), and I helped my Dad do it on his Fat Boy. It gives a very clean look when done.
Don't have a closeup pic of my old RKC, but here is one of my Dad's Fatboy. It happens to be in my garage right now.
Left side -
And the right side.
A dealer is probably going to charge you at least 3 hours labor. They will probably claim they need to extend the wiring. Don't let them convince you of this, they don't. They also may claim that the cruise control wires make the loom to big, it doesn't. Do you have heated grips? If so, that could be a problem. I've done it on my old RKC (which had RKII's), and I helped my Dad do it on his Fat Boy. It gives a very clean look when done.
Don't have a closeup pic of my old RKC, but here is one of my Dad's Fatboy. It happens to be in my garage right now.
Left side -
And the right side.
Road Master
Joined: Jun 2006
Posts: 1,220
Likes: 2
From: iowa
RE: internal wiring on handlebars?
I just finished installing Wild 1 518's on my '06 RKC. I did it myself and could not be happier with them. The local Indie wanted $300-400 and the dealer wanted closer to $500. I started this project on Tuesday and finished final assembly early Friday morning(Tuesday and Thursday were half days at best). Overall I guess it at about 2 full days but you really need to take your time and get this right. I have to differ with one of the above posts that said you did not need to extend your wires. I didn't want to relocate the wire bundle as Wild 1 website recommends so I started with adding 4" to the right side and it worked but went with 6" for the left and I think it was a better fit. As far as cables go I went with Magnum Sterling Chromite II They seemed to have a much more user friendly website to purchase from (But to each thier own) and had the exact sizes I was looking for.I went with 2" longer on the throttle and idle, stock length for clutch and 2" longer for the front brakes. I got my bars from Zanottis, I was looking on their site and found tham for $160 in the Custom Chrome book but it would take my order so I phoned them and they said they were have probs with it and he actually gave me a better price of $151 for the 518's. I think total for just the bars and cables were $525 you can almost double that for labor if you have the dealer do it. It is really a pretty simple and straight forward job as long as you go slow and use your head. Oh, and the manual was invaluable as was HD Forums. Here is one of the most concise and helpful how tos that I have ever seen here on the Forum this guy Rocks https://www.hdforums.com/m_1328001/tm.htm. Hope this helps.
Jeff
Jeff
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Seasoned HDF Member
Joined: Sep 2005
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From: Prescott, AZ
RE: internal wiring on handlebars?
I have done both 513's and 517's on my RG with out extending the wires any
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Road Master
Joined: Jun 2006
Posts: 1,220
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From: iowa
RE: internal wiring on handlebars?
As I pulled my wires loose from the duetsch plug I cut a piece of wire off of the spool I had in the garage. I cut it the same length as the existing wires that came on the stock bars, I then fished it through the new518 bars and you couldn't even see it on the other end.And that had theadded length of what is in the switch housings, with the switch housings in place it would have been about an inch shorter. FYI.
Jeff
Jeff
Outstanding HDF Member
Joined: Mar 2005
Posts: 2,007
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From: Vancouver, B.C.
RE: internal wiring on handlebars?
I just completed (today) putting 513s on my RKC. I needed to extend the hand control harnesses about 6 inches each side.
The 513s (baby apes) have some tight turns so it's a little tough to get the harnesses through, especially if you are running lines for the heated grips.
I swapped out the bars, the stock hand controls and switch covers for chrome ones, added stainless cables for throttle, brakes, and clutch, modded the front fork damper rods, added RaceTech Gold Valves and custom fork springs.
If I don't count time lost for screwups, it took about 50ish total hours to get it all done. Second time around I could knock about 20 hours off that......but I never want to do it again, ever. I can't imagine what the dealer would have charged me.
Like a previous poster, I don't see much sense in swapping out bars and NOT hiding the harnesses in 'em while you're at it.
CN
The 513s (baby apes) have some tight turns so it's a little tough to get the harnesses through, especially if you are running lines for the heated grips.
I swapped out the bars, the stock hand controls and switch covers for chrome ones, added stainless cables for throttle, brakes, and clutch, modded the front fork damper rods, added RaceTech Gold Valves and custom fork springs.
If I don't count time lost for screwups, it took about 50ish total hours to get it all done. Second time around I could knock about 20 hours off that......but I never want to do it again, ever. I can't imagine what the dealer would have charged me.
Like a previous poster, I don't see much sense in swapping out bars and NOT hiding the harnesses in 'em while you're at it.
CN
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