changing handlebars

I cannot get the wiring back through the bars. Does anybody have any suggestions? I hahe coat hanger taped to thwires but just cant pull it around th 90degree ben in new bars.:S

Coat hanger is to stiff try something a little more flexible like an old clutch or throttle cable.

lapeerray wrote:

I cannot get the wiring back through the bars. Does anybody have any suggestions? I hahe coat hanger taped to thwires but just cant pull it around th 90degree ben in new bars.:S

If prefer to retain internal wire routing, could try something more flexible than coat hanger, such as steel fishing line leader wire.

Am guessing you would prefer not yet cutting a relief in the switch case (to allow external wire routing) until deciding whether you really like and want to keep the new handle bars.

Good Luck!

I have used braided fishing line but it's no fun. If you do make sure you put some electrical tape to protect wires and get as close to the terminals as possible. I have also resorted to cutting the terminals off and replacing them. I have also done what Patton said and cut the notch and run them outside. This might also belong in the "what you hate most thread". GLuck!

If there is a "Burr" in the new bars hanging up running the wires, I'd be very careful as now you may have a short in the wiring inside the bars.

MFolks wrote:

If there is a "Burr" in the new bars hanging up running the wires, I'd be very careful as now you may have a short in the wiring inside the bars.

An excellent point by MFolks, especially if the 90 degree turn is a welded joint as opposed to a smoother "pipe-bend" type.

Without a pic or more detailed description, we don't know exactly what is being dealt with.
One of the Z-bar styles (welded joint) would likely be even more difficult to route wires through.

Good Luck!

If there is this "Burr" in the bars, you might have to run the harness externally(not as nice, but easier to trouble shoot). A small Dremel tool with a diamond bit might be able to smooth the burr but not if it is inside a bend or a weld spatter with sharp edges.

A source for electrical supplies;tools,wire,heatshrinkable splices and non adhesive harness tape is at www.waytekwire.com and www.delcity.net .

If you have access to compressed air, a bit of parcel twine or kite string is handy for stage 1. just introduce to sw. hole, block other hbar end hole & blow. string will exit at center hole., tie this to a length of safty wire, and pull thru. safty wire makes a pretty good come-along, as it's small, flexible & strong. It also allows you to stagger incoming wires. a hair drier helps to temporarily soften stiff wires, and lots of WD40. luck g

Thankyou everyone for your input. I think I know now why everone go to drag bars! what exactly is safety wire?

It's usually .032" diameter Stainless Steel used to secure fasteners in Aerospace work. Ask around the race car places
as they have many uses for it.

I might be a little late with this, but you can also spray the wiring with some silicone dri lube, or even rub some car wax on them to help them pull through. I wouldn't use a petroleum based lube because it can eventually break down wiring insulation.
It's a common practice in places like shipyards and construction sites. I knew guys that did nothing but pull wires and cables through conduit.