Enlarge internal wiring hole - Road Glide Forums
Controls & Handlebars Controls and Handlebars for Road Glides

 
LinkBack Thread Tools Display Modes
post #1 of 8 (permalink) Old 11-13-2010, 03:36 PM Thread Starter
gja
Prospect
 
Join Date: Mar 2010
Location: New Hampshire
Posts: 277
Enlarge internal wiring hole

Do people enlarge the hole in the handlebar when doing internal wiring? I have been trying to start wiring, but I can't get all the pins through the hole at once. I have to insert a few, then a few more etc. When I get to the loom, it just doesn't want to fit.

I have been able to feed the wiring from the bottom or the bars and just push them all the way to the grip hole. So the wiring fits, just can't get it started by the upper controls.

I have the Khromeworks +2 sweepers. Any advise would be appreciated.
gja is offline  
Sponsored Links
Advertisement
 
post #2 of 8 (permalink) Old 11-13-2010, 05:16 PM
Member
 
Carisma Audio's Avatar
 
Join Date: Sep 2010
Location: Nothern Maine
Posts: 324
My advise would be try to stagger your wires going into the bars that may help I had fun installing my wires in my monkey bars and if you need to extend the wires make sure to stagger the solder joints it helps out quite a bit
Carisma Audio is offline  
post #3 of 8 (permalink) Old 11-18-2010, 04:37 PM Thread Starter
gja
Prospect
 
Join Date: Mar 2010
Location: New Hampshire
Posts: 277
Put the bars on a drill press and enlarged the holes over the weekend. Much easier to get the wiring in now. Did a test fit with the TBW and upper control wiring. It's a tight fit, but I managed to get everything in.

I did leave off the wire harness covering and am going to just put the covering at the entrance and exit holes on the bars. I'm looking at it like running electrical wire through conduit. Does anyone see any problems with this. The bars are the Khromewerks +2 sweepers. I would say there shouldn't be any sharp edges other than the entrance and exit holes and I have taken a dremel to those to take off any sharp edges.
gja is offline  
 
post #4 of 8 (permalink) Old 11-18-2010, 08:03 PM
Member
 
Roadie09's Avatar
 
Join Date: Sep 2009
Location: Alice, Texas
Posts: 587
When I had the +2 sweepers, I thought they were the hardest bars to internal wire I had ever done. You did the right thing, the entry hole is not large enough to get everything in. If I remember correctly the entry hole is down in the bottom of the dimple (bars can be used with external wiring as well). The dimple creates a choke point where there is already a tight fit.

If it were my bike, I would purchase some heat shrink tubing for the wire loom and install it the entire length. It would keep the wires from rubbing the inside of the bars leading to an eventual short.
Roadie09 is offline  
post #5 of 8 (permalink) Old 11-18-2010, 08:13 PM
Life Member
 
Neano62's Avatar
 
Join Date: Sep 2009
Location: Ohio
Posts: 3,265
Send a message via Yahoo to Neano62
I've got about a 8 page booklet of Instructions that Yaffe sent me w/his 10" Monkey Bars. Shoot me your personnel email address and I'll get them to you, lick-e-t splits! Mite come in handy?


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
[/IMG]
Neano62 is offline  
post #6 of 8 (permalink) Old 11-19-2010, 05:43 PM Thread Starter
gja
Prospect
 
Join Date: Mar 2010
Location: New Hampshire
Posts: 277
Quote:
Originally Posted by Neano62 View Post
I've got about a 8 page booklet of Instructions that Yaffe sent me w/his 10" Monkey Bars. Shoot me your personnel email address and I'll get them to you, lick-e-t splits! Mite come in handy?
Thanks Neano. I managed to get all the wiring in without heat shrink as a test fit. This included the TBW. I took it all back out as I'm powder coating the upper controls to match the paint on the bike.

I spoke with Brian at BR bars and he said he runs his wiring without the heat shrink. He puts it at the entrance and exit of the bars for protection, but inside the bars the wires roam free.
gja is offline  
post #7 of 8 (permalink) Old 11-20-2010, 02:15 PM Thread Starter
gja
Prospect
 
Join Date: Mar 2010
Location: New Hampshire
Posts: 277
Another question.

Bought the twist grip kit (32310-08) without the green plug today. Took it out and there was a third set of wires. There is the black wrap, the yellow wrap and then another black wrap with a black and a white wire. I'm assuming this is for heated grips. I have no plans of adding heated grips, so is it OK to cut this wire back to conserve space in the bars?
gja is offline  
post #8 of 8 (permalink) Old 11-21-2010, 08:18 AM Thread Starter
gja
Prospect
 
Join Date: Mar 2010
Location: New Hampshire
Posts: 277
Thanks to all who helped out. I've got the bars wired and managed to get the protective outer coating in also. Now just need to get the upper control housings to the powder coater.
gja is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Road Glide Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
How To Fix TBW Issues After Internal Wiring Donk Controls & Handlebars 164 07-12-2018 01:11 PM
Internal Wiring CVO Joel Controls & Handlebars 21 02-13-2012 01:23 PM
New Paughco apes for FBW and internal wiring 4getNo1 Controls & Handlebars 32 01-20-2011 08:39 AM
Ok.. Now I am stuck (Handle Bar internal wiring) habu_sake Controls & Handlebars 16 01-11-2011 08:36 AM
Internal Wiring glovergs Do-IT-Yourself 3 09-08-2010 12:47 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome