How to internally wire handlebars (especially bars with sharp bends) - Road Glide Forums
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post #1 of 9 (permalink) Old 10-07-2009, 12:33 PM
The Infamous Sharknose
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Exclamation How to internally wire handlebars (especially bars with sharp bends)

Run heavy string through the bars (using a vacuum or tie a small nut and let gravity pull it though). Make sure you have plenty of string hanging out the hand control end to tape the entire bundle of wires.

Bundle the wires tightly with tape. If you have 13 wires bundle 6 wires together and bundle 7 wires together (2 SEPERATE BUNDLES). This makes pulling the bundles through with the many bagger wires much easier.

Tape the bundled wires tightly to the string. (THE ENTIRE LENGTH OF THE BUNDLE NOT JUST A COUPLE OF INCHES AS IT WILL PULL THE STRING OUT IF BINDING OCCURS). If this doesn't work....tie a slip loop on the string and loop around about 12 inches up the bundle and tape tightly again.

Lubricate the inside of bars with Dawn. It's a messy gooey, black job but it makes it a lot easier.

Now...pull the string through the bars while someone is pushing the bundle and string through the hole where the controls are. REMEMBER, ITS A PUSH/PULL EFFECT. PUSH-BUNCH, PULL SLACK, PUSH-BUNCH, PULL SLACK.

Now take the bars outside with the wires hanging out the bottom of the bars. Wash the soap off the wires. Take laquer thinner and clean the residue of each wire individually.


Finish, drink beer and thank me later....

It's not easy but remember, PIMPIN aint EASY.

.

Last edited by The Infamous Sharknose; 10-07-2009 at 12:36 PM.
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post #2 of 9 (permalink) Old 10-07-2009, 12:40 PM
rippedglide
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Yeah - use a half hitch on the wires! The string will break before the knot comes undone..
post #3 of 9 (permalink) Old 10-10-2009, 06:44 PM
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Make sure the holes in the bars are absolutely burr less. take a piece of 250 grit sand paper and clean around the holes in the bars to ensure you will not nick or scratch any of the wires.


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post #4 of 9 (permalink) Old 10-21-2009, 06:08 AM
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Good advice and suggestions. I always cut the electrical cords off "dead applicances" and save the wiring for this type of fishing. Amazing just how many times I've used individual wire stands out of an old 30' long vaccum cleaner cord.

Never throw anything out and my garage looks like it too.

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post #5 of 9 (permalink) Old 12-08-2010, 12:05 AM
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Cool Day 2

Yesterday I pulled my ride apart, did some wire work I wanted and broke her down for the 12" Monkey bar install.

Day 2 I started the wire pull. Now pay close attention, after purchasing wire extention kit from yaffie. I noticed no TBW kit, called Paul and in his own arrogant way let me know it was not needed, I asked why he sold it to me? Well dude was right I pulled all the wires using all the stock covers, had my wife help keep pressure on wires as I fished, took a few hours with some WD and KY on right, dry for left. Reroughted clutch and brake line. To see how it handles without extending. I'll keep ya up to date. Now remember I'm a disablied dude with a bad back and bumb legs. If I can do it Anyone can. Oh yea, did I mention I got anger issues? Well didn't have to lose my cool. Merry Christmas all and God Bless you all, your bro Frodoe
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post #6 of 9 (permalink) Old 12-08-2010, 06:57 AM
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Frodoe, just curious why you got the extention? Paul has told me several time through email that the stock wires and cables are long enough to go up to 12"?

Greg
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post #7 of 9 (permalink) Old 12-08-2010, 01:47 PM
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I used a broken throttle cable and it worked great. I guess that was one good thing that came out of my broken throttle cable back in the spring .
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post #8 of 9 (permalink) Old 12-13-2010, 09:48 PM
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If you hot some home electrical wire around the house, strip it and use the ground wire, works great!

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post #9 of 9 (permalink) Old 12-16-2010, 11:25 AM
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Yaffe said I need it

Quote:
Originally Posted by ncbeast View Post
Frodoe, just curious why you got the extention? Paul has told me several time through email that the stock wires and cables are long enough to go up to 12"?
Yaffe said that I was going to have to have it, after calling about TBW tune changed?
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