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post #1 of 13 (permalink) Old 07-28-2012, 02:56 PM Thread Starter
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Unhappy I hit a snag on bar install

I was installing 11" Santee mini apes and was not going to run the wires internally until winter, WRONG. I will be running them inside now because the holes to run them internally don't leave enough room to run them on the outside like the dimples on the stock bars do. Not enough time today, looks like I'll be down for a while. Ideas anyone?


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post #2 of 13 (permalink) Old 07-28-2012, 03:04 PM
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I was installing 11" Santee mini apes and was not going to run the wires internally until winter, WRONG. I will be running them inside now because the holes to run them internally don't leave enough room to them on the outside like the dimples on the stock bars do. Not enough time today, looks like I'll be down for a while. Ideas anyone?
I had the exact same issue with my Wild Ones Outlawz. It took (first time I ever changed bars) between 8 to 10 hours to get it done....


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2011 FLTRU Because Momma wants me to be happy and because we all know deep down in our hearts that black bikes are faster! Thundermax TBW with Tman 555 tq cams, Drago's Dragula 2:1 exhaust and a Big Sucker. Lowered 1" with Progressive Monotubes and Ohlin 3-3s. SG rear facia, BAL-1, Daymakers, Diamond Plate Collection, 16" Madstad, J&M Rokkers with Bazooka 200.4 amp, Lenale fan, Harley Road Zepplin, 12" Wild Ones Chubby Outlawz and a G-Max 205-55-16 rear tire.
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post #3 of 13 (permalink) Old 07-28-2012, 03:05 PM
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my Khrome Werks 2+2 sweepers are supposed to be internal , but no way all them wires is going in the bars , no dimples like the other bars , so I just left em out and werks fine

JtB

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post #4 of 13 (permalink) Old 07-28-2012, 04:43 PM
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Take your time and be patient?

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post #5 of 13 (permalink) Old 07-28-2012, 05:28 PM
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Not a big deal, just go at it, you'll be done before you know it.

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post #6 of 13 (permalink) Old 07-28-2012, 05:32 PM
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my Khrome Werks 2+2 sweepers are supposed to be internal , but no way all them wires is going in the bars , no dimples like the other bars , so I just left em out and werks fine

JtB
LOL, I can relate to that. When I had KW+2 bars on the bike, I got all the left side wires in just fine. But, when I started in on the right it was a nightmare. I ended up with the left side internal and the right outside. I had a ride the next morning and finally had enough, just put the bike back together that way.

When I swapped those out for the WO518 bars, no option but do the internal wiring. It was way easier.
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post #7 of 13 (permalink) Old 07-28-2012, 07:34 PM
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I ran mine internal the first time and had the green clip separate partially on me so had to do it a second time. The second time I ran the throttle wires internal and the control wires external.

What I did was drill a hole in the bottom of the bar just beyond the switch housing and feed the control wires thru it and follow the profile of the bars into the fairing. I used a leather crash bar cover to keep the wires against the bars since the indents that were on the stock bars did not exist on the aftermarket bars. I used a second leather wrap on the left side for symmetry. This looks good if you have black bars. If you have chrome bars look for a holder in Dennis Kirk that will match the diameter of you bars.

The leather crash bar covers can be purchased from Capt-itch.com. They have some cool leather products.

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post #8 of 13 (permalink) Old 07-29-2012, 01:57 AM
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I ran mine internal the first time and had the green clip separate partially on me so had to do it a second time. The second time I ran the throttle wires internal and the control wires external.

What I did was drill a hole in the bottom of the bar just beyond the switch housing and feed the control wires thru it and follow the profile of the bars into the fairing. I used a leather crash bar cover to keep the wires against the bars since the indents that were on the stock bars did not exist on the aftermarket bars. I used a second leather wrap on the left side for symmetry. This looks good if you have black bars. If you have chrome bars look for a holder in Dennis Kirk that will match the diameter of you bars.

The leather crash bar covers can be purchased from Capt-itch.com. They have some cool leather products.
Thats a nice way to go about it. When you drill your hole make it the same size as the wire opening that came with the bars and after its drilled out take a right angle cut off tool and cut a channel between your drill hole and the one that came with the bars. That way you will not have to undo the plug end of the wires. just lay them in the channel. Then take a rubber gromet and cut it in half and J-B weld it to the inside edge of your drill hole.
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post #9 of 13 (permalink) Old 07-29-2012, 09:48 AM
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Thats a nice way to go about it. When you drill your hole make it the same size as the wire opening that came with the bars and after its drilled out take a right angle cut off tool and cut a channel between your drill hole and the one that came with the bars. That way you will not have to undo the plug end of the wires. just lay them in the channel. Then take a rubber gromet and cut it in half and J-B weld it to the inside edge of your drill hole.
That thought crossed my mind when I did mine, but I was concerned about weakening the bars. I just fed the wires in then back out the hole I drilled. It really wasn't that hard to do. I also filed the edges of the hole real well to take out any sharpness and used a Q-tip to add some paint to the bare metal.

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post #10 of 13 (permalink) Old 07-29-2012, 11:42 AM
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Originally Posted by Electricfoot View Post
I was installing 11" Santee mini apes and was not going to run the wires internally until winter, WRONG. I will be running them inside now because the holes to run them internally don't leave enough room to run them on the outside like the dimples on the stock bars do. Not enough time today, looks like I'll be down for a while. Ideas anyone?
Just go for it and use the bars as they were designed. No internal wiring job is exactly painless on these bikes but at least you've bars with smooth bends that will be far easier to wire compared to some of the others. There are several good how-to threads in this section. Just make sure to either hard wire the TBW wires to eliminate the green connector, or do as I did and extend the wires so the green plug lives in the fairing. It's a little daunting the first time and I was in no hurry but I figure the next time it'd only take me about 4 - 5 hours.

-phil

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