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Old 07-19-2004, 09:27 AM   #1 (permalink)
Join Date: May 2003
Location: Napa , California
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2k2FXDL wants to know Dino or Syn?
Wiring inside handle bars

I am going to change the handle bars on my 02 FXDL soon and would like to run the wiring inside the bars, is this a tough job to do? looks like a lot of wires, do I leave the outer covering on the wires or remove it and do each wire one at a time? what about grommets in the holes?
thanks, Gene
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Old 07-19-2004, 09:38 AM   #2 (permalink)
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Location: Oklahoma
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jethro wants to know Dino or Syn?
if you have fat bars just take plug ends off of wires and run a wire through your bars and pull pull pull. Sometimes it goes easy sometimes its a real *****. use a string with nut on it to go threw bars first. then tape up your harness end and use a wire or some thing you can pull on to pull the harness through be care full and dont pull to hard buddy pulled butt connectors off once.
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Old 07-19-2004, 11:33 AM   #3 (permalink)
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wayne1967 wants to know Dino or Syn?
I just got through putting apes on mine and had to lengthen the wiring. I left about 3inchs of the stock covering to push into the bar's hole when I was done. I had to cut all the wires and solder on a 8" section to each. I used red #18 wire and marked the ends that came through the base of the bars with black bands. ie. one band=black, two=white, three=yellow and so on. It ain't hard just write everything down.
Christian, American, Pro-gun, Conservative, any questions?
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Old 07-19-2004, 04:33 PM   #4 (permalink)
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Big Mac wants to know Dino or Syn?
I just finished installing a set of Wild 1 501 Pullback Drag Bars on my 03 Night Train. If you have a service manual, removing the gas tank to access the wiring harness is not a problem.

Running the wiring through the handlebars is not a problem either if you remove the wiring loom. I simply tied a small nut onto some dental floss and ran it through the handlebars. I then tied the dental floss to a shoe lace and pulled the shoe lace throught the handlebars. Finally, I staggered the wires and taped them on the shoe lace and pulled them through the handlebars. Once the wires were through the handlebar, I re-installed the loom on the wire outside the handle bar.

I was initially concerned that I might have to increase the length of the wiring, but they fit with room to spare. However, my clutch cable, throttle cable, and idle cable are too short and I am waiting on a set of Barnett stainless steel cables to arrive so I can finish the install and start riding again.
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Old 07-19-2004, 06:52 PM   #5 (permalink)
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Paniolo wants to know Dino or Syn?
This makes it real easy.

Get a ShopVac. Place as many fishing lines as wire in the end holes. Vacuum them to the other side. Dump baby powder inside the bars. Attach the wires to the fishing lines and pull them through.
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