Hi All, for 2 days now I have struggled to feed wires through the right side of my new 14" Klock werks apes. I can get one harness , or the other through quite easily( referring to the fly by wire harness and the right controll harness.) MANY tools thrown, many feed wires/ string broken half way through. Have tried one then the other, then the other way around etc..... Have used grease. Is there something im missing? The bars are fat apes 1 1/4" but it seems almost impossible to get BOTH through the bar, is there a sequence? one then the other? .......Please any advice would be helpfull at this point.......Oh, and where can you get new pins for connectors? one bent over and broke off will trying to pull through......Thanks in advance any and all who can assist. Cheers. Dale

 

maybe too late with the grease, but cornstarch/ talc can be an easy wire lube.

to fish, I often heatshrink the new wiring to the fish wire or fish tape and pull through

make sure there are no burrs that catch and grab the wiring

just take patience

mike

 

I've wired 2 different sets of bars. The first a set of PYO 1 1/4. I used dawn dish soap. Grease on hot days will forever drip out and on to your fender. Lots and lots of patience. I did mine on my kitchen table and had to walk away several times in fear of throwing them through my patio door... lol After doing all that I found another set of bars I liked more and pulled them back out after having them in. I probably could of sold the bars for 3 times what I paid for them had I let the wiring in them. It took me about a week of working them on and off to get them done. The 2nd set of bars were Sweeping K'9's 1 1/2 thick. Literally took less then 15 mins to get both sides run through the bars. I didn't use any lube running them through these bars.

 

I used the Yaffe method using welding wire. I ran the TBW first and cut out green plug soldered shrink wrapped. I ran the TBW first using 8mm shrink tubing and the big bundle last using 10mm shrink tubing. Also used Ideal Clear Glide for lube got it at Lowes.

 

Cut, solder , and heat shrink tubing , in that order. Get rid of the green TBW plug and the black heated grip plug. It will make it a lot easier to pull without those bulky plugs. I use Vaseline, it works great, but I've also heard powder work well also. I also used nylon cord to pull the wires. Tie at top and half hitch five or six places down, then wrap real tight with electrical tape. I've never had a wire joint pull apart on 6 sets of bars that I've installed.

 

I'm about to tackle this operation myself on a set of LA Chopper 10" Twin Peaks. I'm certainly appreciative of all the tips and advice I've read on here this far.
I'm not a tool thrower, but who knows after a few glasses of bourbon.

Good luck!

 

One other thing that hasnt been mentioned and that is to stagger the splice soldering so they are not all in the same place....verty very important.

 

I hear your pain!!! I pulled weed eater string, fishing line, used wd40, powder, everything!!! Rubbed insulation off the wires, broke connectors, had a jumbled mess.

Clint Eastwood said, "A man's got to know his limitations."

I said to heck with it, threw in the towel, and called BR Custom Bars. They were super nice, and sent me a set of bars Pre-wired!! That was about 7 months ago, and I couldn't be happier.

Best of luck to ya - whichever route you take.

 

Good point Tucci I didn't have to extend my control wires as my bars were shorter and ran harness under radio.
Below is some install info notes maybe it'll help OP and others!

Got the install done basically following Yaffe instructions. Harbor Freight was jackpot for materials! I used Carbon Steel Welding wire .0123" thin wire but strong won't break! I used .095 weedwacker line to thread welding wire. Used 2 sizes ofshrink tubing 10mm x5M & 8mm x 5M. I used the 10mm shrink for left & right control wire bundles. Used the 8mm shrink for the TBW sensor bundle. I did cutout the infamous green TBW connector eliminating it and soldered and shrink wrapped. Picked up up bottle of Ideal Clear Glide at Lowes for lubing wire bundles and it worked out good.
Harbor Freight item numbers
10mm x 5mm Shrink wrap 98067 $2.99
8mm x 5mm Shirnk warp 98066 $2.99
Welding wire .023 4" spool 42915 $5.99

Here's the TBW green connector wiring elmination got from another forum .

Next is to draw a diagram of the two ends of the green connectors so you know which wires to connect when we cut off the connector. HD has split the wires coming from the sensor into two group with two different color shrink wraps:Black and Yellow. I will now refer to these as Black side wires and yellow side wires. Each side has a white wire, black wire, and red wire. This is what it looks like:
Here is how the wires will hook up.

Blue Wire------(Black Side) White Wire

Brown Wire----(Black Side) Red Wire

Black Wire-----(Black Side) Black Wire

Grey Wire-----(Yellow Side) Black Wire

Red Wire------(Yellow Side) Red Wire

Purple Wire----(Yellow Side) White Wire

 

Thanks everyone....fantastic info. Removing green TBW connector, soldering, and going to heat shrik the bundles before pulling them through. Gotta pic up some of this glide lube from lowes, as the only lube I have on hand is used for other things..... Cheers!!!