Hiding wires inside the bars
#1
Hiding wires inside the bars
I just ordered Chrome Housings and lever perches for my RK, and all the SS front end pieces: Brake Lines, Throttle, Clutch. I figured since I'll have the whole handlebar set torn down I may as well route the wires through the bars.
I saw a writeup about drilling a hole under the switch housing and another between the risers, but I still have a few questions.
Are there any issues with length of the wire?
Will the wires fit inside a standard handlebar?
Since I'll have the switch housings apart would it be easier to feed the wires from under the risers to the switches, or do I still have to take the connecting plugs off the nacell end of the wires?
Thanks,
J
I saw a writeup about drilling a hole under the switch housing and another between the risers, but I still have a few questions.
Are there any issues with length of the wire?
Will the wires fit inside a standard handlebar?
Since I'll have the switch housings apart would it be easier to feed the wires from under the risers to the switches, or do I still have to take the connecting plugs off the nacell end of the wires?
Thanks,
J
#3
RE: Hiding wires inside the bars
The diameter of the bars is not a problem, I ran the wires inside a set of RK High bars and they're not any bigger than the stock bars. I had no problem with the length of the wiring. You take the individual wires apart from the connector behind the headlight, make yourself a map of what color goes where and then put it all back together. It really cleans up the front end.
#5
#7
RE: Hiding wires inside the bars
When you make the holes in the bars to run the wires, make extra sure you deburr the holes, and also edge treat the area with a good coat of primer and paint, you don't want rust to start and then the chrome will begin to lift and crack.
As far as pulling the wires from the grip side, same as from the bottom.
Insert a good strong pulling wire through, tie off wires you want to pull and gently feed and pull through.
As far as pulling the wires from the grip side, same as from the bottom.
Insert a good strong pulling wire through, tie off wires you want to pull and gently feed and pull through.
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#8
RE: Hiding wires inside the bars
ORIGINAL: bountyhunter
Will save a lot of grief by getting fatter bars, designed for internal wiring! Hey, is that a new paint job?
Will save a lot of grief by getting fatter bars, designed for internal wiring! Hey, is that a new paint job?
Went with 1-1/2" diameter bars on mine - now 1" bars on a bagger look like toothpicks stuck in a marshmello to me. Note that 1-1/2" bars require a riser clamp change. Most 1-1/4" bars, like Chubbys, have a standard 1" clamping area but still recommend changing to a 1-piece clamp.
IMPORTANT: whichever way you choose replace the stock rubber riser bushings with polyurethane (H-D 56298-03 or equal) to keep your bars from sagging over time.
Wiring & cables should reach if you don't change the bar dimensions (pull-back, width & rise) too much.
#9
#10
RE: Hiding wires inside the bars
JM , check this out.
https://www.hdforums.com/m_262490/tm.htm
Deburring the holes cannot be over stressed.
Pretty good how-to for this project and a link for more.
Mick
https://www.hdforums.com/m_262490/tm.htm
Deburring the holes cannot be over stressed.
Pretty good how-to for this project and a link for more.
Mick