Well... I spent about 4 hrs trying to do the internal wiring on my Carlini's last night. Ran the left side no problem but caught hell trying to do the right side with the TBW and other harness. I did everything I could to make them as small as possible buy staggering the splices, soldering the wires and using shrink wrap. On the third attempt the damn thing got stuck in the bars and wouldnt come out. Finally got it out but cut and destroyed some of the wires doing it. Anyway, this morning I took the bars to the shop to have them do it. Will have the bars back by Tues.. Cant belive I couldnt get it! Sucks but what you gonna do?

 

It is not impossible. One advantage to getting older is learning patience and that walking away from something difficult and returning later usually results in finding a solution. Several things come to mind, but you have already given up. Hope they don't rape you too bad.

 

For future reference. You have to shrink wrap both sets of wires. You already did good by staggering splices. But What you may not have done was use some sort of slickem. I would have used actual electrical wire soap but to keep from buying it I used what I had around the house, petroleom jelly, aka vaseline. It don't take a lot, just a thin coat on the wire bundles. Pull with the lead line, I used a piece of mig wire, and feed the tail. May take a few tries but that's how I did it.

 

I wired my Wild 1's in about 15 minutes. They are the 14" 576's and I had JUST enough wire to make it through the bars BEFORE i extended the wires...Sucked a cotton ball with a dental floss tail through the bars, tied the floss onto the stock wires and gently pulled them through. Then I added the NAMZ extensions I got from Johnny Vaughn. Slicker than slick.
(I realize this approach won't work on taller bars.)

 

Now just imagine that in 6 1/2 hours at the dealer the whole job ( wires extended, run internally, clutch cable and brake lines) would have been complete and youd be riding it.

Most bars that come "pre drilled" need a lot of work on the holes so that the wires will pull through and not get tore up. Takes a light touch with a die grinder to get the edges so that they are not sharp. Did a set today and will do another tomarrow.

 

Hate laugh but... I can feel your frustrations in your words brother! Especially the last 2 sentences! But, you knew when enough was enough, give it to the pro's & F' it!

 

mine were a biotch also. I sprayed a little WD40 in the bars, but it was really just trial and error to get them through. My big snag was my TBW cutouts in the bars were too small, and it wouldn't fit. Just got the file out and worked it for awhile until it fit like a glove. I just made sure my solder joints were good and shrink wrap was tight, then wrapped them VERY tight with electrical tape. The yanking didn't do any harm then.

 

Fettle all holes with a needle file , or small modelers grinder until completely smooth, if you can twist your little finger round inside the hole with no stitches required your ready to install...lol

 

Yeah, I did the shrink wrap and WD40 but still couldnt get it. I did intend on doing it again till I DESTROYED the wires getting them out on the last attempt. I did not file the holes so that would have been good to know. The holes on the Carlini bars are very small.. The stock handlebars have way bigger holes.Anyway, the pro's got it now and it will be done. By the way, my freakin fingers and thumb are still sore as crap!

 

Just did the Klock Werks +2 sweepers yesterday, wasn't too bad. Course I have the outer and inner fairing off ( getting painted) and that I'm sure helped a lot. I found that folding back the black connector and pulling the green connector through first followed by the black connector made it easy. Both wound not go through the indent area of the bars.

Just some FYI ( you old dogs know about this) I used military trip wire as a pull wire. Tough as nails, won't brake and easy to wrap around the wires...worked great. If you can score some it's nice to have around.