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Discussion Starter #1
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.
 

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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
 

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Discussion Starter #3
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.
 

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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.
 

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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?
 

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Discussion Starter #6
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.
 

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Discussion Starter #7
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?
 

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Discussion Starter #8
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.
 
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