Bob and Mark give us some tips on how to pull that Harley wiring through the handlebars. They remind us perfect practice makes perfect. Why have your first try be on your new bars? Practice on the stock bars and some wiring. Take the extra time and practice before you do the real install.
One Response to “Tip on Pulling Wires Through Handlebars”
Henry T. Kramer
Take a kite string & use a shop vac to suck the string through the handlebars. Then tie the string to the wires
& pull them through.
I just wanna take a moment and review the stock bar configuration and just a few tips that may be helpful when it comes to stringing the wires in the bars. Obviously the factory bars are a smaller diameter. Three quarter inch, as opposed to inch and a half. But it doesn't change the fact that you have to be crafty. You have to be tricky in order to get more than one single wire. For example, if you had eight wires in one plug, you're dealing with four pair of wire. So you've got two, four, six. I've got eight pieces of spare wire here. These bars are not meant to be internally wired. They do have the holes for the external harness retaining clips. But it does have a center hole where the throttle by wire harness exits. Just take a few minutes. Just start practicing without any coating, any covering, any string. You'll see this is a nice, shallow bend. See where the wires go. Just wanna run everywhere. That's what makes it important that you bunch the wires together as tight as you can. Make a nice taper with the string and the electrical tape. And you can see they just about come to the bottom. Now, this is a very short span. I'm using approximately the amount of wires outside dimension that you would be pulling through with a string and you'll see how easy they went through. Once you start getting into a nice, long section and you make that very tight 90-degree bend, a lotta things change. So if you have the opportunity, practice on your old bars. Take the time. Run the string. Use more wire than what you're gonna pull through the new bars. Always do practice runs. Always try and check for fitment. Try and check for new procedures on an old set of handlebars. Don't get frustrated. Don't get in trouble working on the new component that you're gonna install on the motorcycle. Practice, practice beforehand. Saves a lot of frustration during the actual install.
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Take a kite string & use a shop vac to suck the string through the handlebars. Then tie the string to the wires & pull them through.