Looking for any tips from those who have upgraded handlebars to ape hangers (12" KSTs is what I am going with). I have read many threads on pulling the wires. Would it have been easier to buy wire extensions and run those first? I need to find a video before I get started.

 

NAMZ makes a new kit (NHCX-CB14) that replaces the factory switch harness with a longer set of wires. You can use these on up to 18" bars. I've installed 12" bars on several Rushmore bikes, and one issue that I have is having barely enough wire sticking out the center section to connect the extensions to. This harness would assist with this issue.


When you run the wires, pad the bars and put them in a vise. Use a liberal amount of WD-40 and spray down the bars from all openings. This really helps getting the wires to pull through.

 

I just did 12" monkey bars on my 2016 and pulling the wires was sooooo much easier than on my previous 2012. I bought the plug in switch pack extensions from the dealer. When pulling the wires I used a little lube on the throttle side, none on the other. Just feed slack in and pull it out. After the wires are pulled they just make it out the end of the bars so you can then just plug your extensions in

 

I was thinking to run the extensions through the bars then attach the wiring harness. What I am reading is run the stock wires and then add the extensions?

 

I put 12" KST Mayhem Bagger Bars on my '14 limited. I should have bought the extension but I am cheap and made my own(time consuming but worth it)I staggered the splices and wrapped it all in black tape. Used weed eater line to pull it through and used dish soap to lube it. BE CAREFUL pulling over the crown in the bars because there is probably welding slag in there.

 

If you choose to run the 4", 8", 12" extensions, what you would do is run the stock harness through the bars and then clip on the extension; you definitely do not want to clip the extensions on and then attempt to run it through the bars like that.


The kit I referred to in my earlier post is a longer replacement for the stock wiring...

 

I stagger and solder the extensions on first, if you push then pull a little at a time you wont have any trouble. Internally wiring the bars is the most time consuming part of the job, take your time so you don't have to do it twice.
I use Guerilla Cable Exts. One more thing don't attempt to use that green plug 9 times out iof 10 that POS will give you problems,either cut and solder or get the CVO TBW (make sure the connector pins are correct)

 

Echo6. Does the kit have both left and right wires?

 

Yes, it does. These are longer wires for the left & right side controls only. You don't need an extension for the TBW as there is more than enough slack there.


I found the kit cheapest at Direct Cycle Parts. It's PN 2120-0783 on their site.

 

Great thread, I spent about 2 hours today trying to run all my wires internally for my 2014 FLHTK and Todd's Cycles Bars this morning. Finally had to walk away for a while. The left side has 3 wire to run, man are they proving interesting to get through. Would love any and all tips for feeding these things. Will try the WD-40 and weed eater line tomorrow night.