 running electrical inside handlebars?
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Joined: Jan 2011
Posts: 379
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OP
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Joined: Jan 2011
Posts: 379 |
i know i saw a really great tutorial on this on here; but i will be darned if i can find it. anyone feel like helping me out over here?
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Re: running electrical inside handlebars?
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Joined: Feb 2005
Posts: 20,096 Likes: 2
Fe Butt
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Fe Butt
Joined: Feb 2005
Posts: 20,096 Likes: 2 |
Yep! Just like a good Single Malt Scotch, you might call me "an acquired taste" TOO.(among the many OTHER things you may care to call me, of course)
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Re: running electrical inside handlebars?
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Joined: Jan 2011
Posts: 379
Adjunct
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OP
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Joined: Jan 2011
Posts: 379 |
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Re: running electrical inside handlebars?
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Joined: Feb 2005
Posts: 20,096 Likes: 2
Fe Butt
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Fe Butt
Joined: Feb 2005
Posts: 20,096 Likes: 2 |
De nada, Amigo! 
Yep! Just like a good Single Malt Scotch, you might call me "an acquired taste" TOO.(among the many OTHER things you may care to call me, of course)
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Re: running electrical inside handlebars?
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Joined: Mar 2009
Posts: 12,964
Stickman Yogi
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Stickman Yogi
Joined: Mar 2009
Posts: 12,964 |
I've wanted to do this since I got my bike. Would appreciate any comments you might have as you go about this.
Live to love, love to live.
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Re: running electrical inside handlebars?
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Joined: Jul 2006
Posts: 853
3/4 Throttle
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3/4 Throttle
Joined: Jul 2006
Posts: 853 |
It is not hard...just follow the post...I have done 3 sets of bars now...I didn't get the colored wire I got a book of wire tags (electrical dept at hardware store) and tag both ends of the wire...wrote that number down on the wire schematic. I also wrapped the twisted wires with primary wire (Radio Shack) before soldering. This provides a mechanical connection along with the solder connection. Primary wire is a very small wire that is wrapped around the two wires after you twist them together. You can also google solder connections allot of You Tube stuff.
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Re: running electrical inside handlebars?
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Joined: Feb 2007
Posts: 23,227 Likes: 62
Fe Butt
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Fe Butt
Joined: Feb 2007
Posts: 23,227 Likes: 62 |
Do the job with the bars off the bike it makes it much easier.
I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
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Re: running electrical inside handlebars?
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Joined: May 2006
Posts: 2,647
Loquacious
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Loquacious
Joined: May 2006
Posts: 2,647 |
I used sandman's directions to do mine too, and as dog said, it's easier to do with the bars off.
06 America 904
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Re: running electrical inside handlebars?
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Joined: Mar 2005
Posts: 1,284
Learned Hand
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Learned Hand
Joined: Mar 2005
Posts: 1,284 |
Make sure you stagger your splices so you don't end up with a big pregnant harness.
Strangler
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Re: running electrical inside handlebars?
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Joined: Mar 2008
Posts: 1,586 Likes: 1
Learned Hand
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Learned Hand
Joined: Mar 2008
Posts: 1,586 Likes: 1 |
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Re: running electrical inside handlebars?
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Joined: Jun 2011
Posts: 319
Adjunct
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Adjunct
Joined: Jun 2011
Posts: 319 |
This was done to my bike with the prior set of bars on it...I know it took Al a long time to do this, but when I went to undo this to put on a different set of bars, it was a NIGHTMARE!! My advice, color code ALL of the wires and stagger connections...label, take pics or videos...unless you are permanantly keeping them that way! Just a heads up
02 TBA Cardinal Red/Black
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Re: running electrical inside handlebars?
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Joined: Jan 2011
Posts: 379
Adjunct
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OP
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Joined: Jan 2011
Posts: 379 |
Quote:
This was done to my bike with the prior set of bars on it...I know it took Al a long time to do this, but when I went to undo this to put on a different set of bars, it was a NIGHTMARE!! My advice, color code ALL of the wires and stagger connections...label, take pics or videos...unless you are permanantly keeping them that way! Just a heads up
Ha! Obi Wan (Al) will be helping with mine. It is staying that way forever...we had commented that to change your bars out must have been a nightmare!
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Re: running electrical inside handlebars?
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Joined: Oct 2011
Posts: 115
Adjunct
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Adjunct
Joined: Oct 2011
Posts: 115 |
What do you guys do with the brake and clutch switches?
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Re: running electrical inside handlebars?
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Joined: Jul 2006
Posts: 853
3/4 Throttle
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3/4 Throttle
Joined: Jul 2006
Posts: 853 |
I took my clutch switch off and brake switch hooks up like before...I will take a pic later
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Re: running electrical inside handlebars?
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Joined: Oct 2011
Posts: 115
Adjunct
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Adjunct
Joined: Oct 2011
Posts: 115 |
From what I gather on the wiring diagram, the diode pack provides ground to the starter switch from either the neutral switch OR the clutch switch. If the clutch switch is removed, then the starter switch can only receive a ground by way of the neutral switch...meaning the starter will only turn over if you are in neutral. Sounds fine to me! I'm sold...bye bye clutch switch. I'd love to see how you routed the brake switch...that one I kinda need. Although I don't do a whole bunch of braking with just my front brake unless I'm coasting up to a stop. Even so, the brake switch needs to stay.
Last edited by Hankster; 06/19/2012 10:35 PM.
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Re: running electrical inside handlebars?
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Joined: May 2006
Posts: 2,647
Loquacious
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Loquacious
Joined: May 2006
Posts: 2,647 |
I got dimpled bars, so the wires ran right up under the switch housing all nicey nicey. I've seen it though where people have cut out a small notch in the switch housing, enough to run the wires back under and through the bars.
06 America 904
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Re: running electrical inside handlebars?
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Joined: Oct 2011
Posts: 115
Adjunct
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Adjunct
Joined: Oct 2011
Posts: 115 |
I have drag bars, so I am thinking my only option is to notch out the housing a bit. I am definately going to remove the clutch switch...that thing sticks right out in the open and there is really no way to tuck that harness back up under the housing without it looking pretty bad (IMO). Besides, what's so bad about your bike only being able to start in neutral?
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Re: running electrical inside handlebars?
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Joined: Jul 2006
Posts: 853
3/4 Throttle
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3/4 Throttle
Joined: Jul 2006
Posts: 853 |
 The wire comes out of the switch housing on the bottom and plugs into the brake switch...black wire with the blue connectors On the clutch switch I pull the switch out of the housing...there is a hole there and some day I go Ace Hardware and find a plug for it. I also got rid of the side stand switch.
Last edited by SDKimo; 06/19/2012 11:16 PM.
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Re: running electrical inside handlebars?
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Joined: Jul 2006
Posts: 853
3/4 Throttle
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3/4 Throttle
Joined: Jul 2006
Posts: 853 |
One other thing I did as buy another set of handbar switches and wired up a drag bar...so I can run a drag bar when I want to because every thing is plug and play...un-plug the min-apes and plug in the drag bars...
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Re: running electrical inside handlebars?
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Joined: Oct 2011
Posts: 115
Adjunct
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Adjunct
Joined: Oct 2011
Posts: 115 |
Thanks for the picture. I wish there was an internal switch...bummer.
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Re: running electrical inside handlebars?
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Joined: Feb 2007
Posts: 23,227 Likes: 62
Fe Butt
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Fe Butt
Joined: Feb 2007
Posts: 23,227 Likes: 62 |
You could disable that clutch switch but then the starter would work any time you press the button, no matter what gear or anything else. I may actually do that to clean that wire up too.
I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
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Re: running electrical inside handlebars?
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Joined: Jul 2006
Posts: 853
3/4 Throttle
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3/4 Throttle
Joined: Jul 2006
Posts: 853 |
Mine is press and go, no matter what gear...I came over from a Harley, they did have clutch switch and didn't have the side stand switch either...
So I all ways start the bike in N and have the the clutch pulled in and then check the side stand after I kick it into gear...Just the way I leaned how to do it...
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Re: running electrical inside handlebars?
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Joined: Oct 2011
Posts: 115
Adjunct
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Adjunct
Joined: Oct 2011
Posts: 115 |
Dog33...Disabling the clutch switch actually does the opposite of what you stated and will ONLY allow the engine to turn over when in neutral(regardless of clutch position). The clutch switch allows the engine to turn over no matter what gear it is in as long as the clutch is pulled in...UNLESS...you disbled it by shorting the wires together. Then it would allow the engine to turn over in any gear regardless of clutch position...as you stated.
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Re: running electrical inside handlebars?
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Joined: Jul 2006
Posts: 853
3/4 Throttle
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3/4 Throttle
Joined: Jul 2006
Posts: 853 |
Now that you posted that...I connected the wires together and the same for the side stand switch...so mine will start in gear
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Re: running electrical inside handlebars?
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Joined: Feb 2007
Posts: 23,227 Likes: 62
Fe Butt
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Fe Butt
Joined: Feb 2007
Posts: 23,227 Likes: 62 |
Quote:
you disbled it by shorting the wires together. Then it would allow the engine to turn over in any gear regardless of clutch position...as you stated.
That is what I meant.
I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
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Re: running electrical inside handlebars?
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Joined: May 2011
Posts: 754
3/4 Throttle
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3/4 Throttle
Joined: May 2011
Posts: 754 |
Quote:
One other thing I did as buy another set of handbar switches and wired up a drag bar...so I can run a drag bar when I want to because every thing is plug and play...un-plug the min-apes and plug in the drag bars...
Now this IS a pretty keen ideer! 
Karl
Odessa, MO
'07 America, Cinnamon Girl (aka: Black Beauty or Ol' Penny) - Sit Down, Shut Up & Hang On
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Re: running electrical inside handlebars?
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Joined: Jan 2011
Posts: 379
Adjunct
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OP
Adjunct
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Posts: 379 |
getting ready to do this finally. does anyone know what the colors are that i need? and yes i am that anal.
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Re: running electrical inside handlebars?
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Joined: Feb 2005
Posts: 20,096 Likes: 2
Fe Butt
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Fe Butt
Joined: Feb 2005
Posts: 20,096 Likes: 2 |
Yep! Just like a good Single Malt Scotch, you might call me "an acquired taste" TOO.(among the many OTHER things you may care to call me, of course)
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Re: running electrical inside handlebars?
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Joined: Feb 2007
Posts: 23,227 Likes: 62
Fe Butt
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Fe Butt
Joined: Feb 2007
Posts: 23,227 Likes: 62 |
I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
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Re: running electrical inside handlebars?
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Joined: Jan 2011
Posts: 379
Adjunct
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OP
Adjunct
Joined: Jan 2011
Posts: 379 |
thanks to the skill of SSjones, my stealth wiring is almost done 
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Re: running electrical inside handlebars?
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Joined: Mar 2013
Posts: 2
Complete Newb
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Complete Newb
Joined: Mar 2013
Posts: 2 |
curious if you guys know how much taller of a bar you could put on before needing to get longer cables and or electrical extensions for a 12 speedmaster. I scored some 14in. nos apes 36in wide curious how they would fit. Eyeballing looks close.
i like my motorcycles like my women, fast, dirty and cheap
12 Speedmaster/67 Tiger 650/78 xs650
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Re: running electrical inside handlebars?
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Joined: May 2010
Posts: 5,720
Check Pants
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Check Pants
Joined: May 2010
Posts: 5,720 |
You are going to need to buy longer control cables and splice in the wiring. 14" Apes will definitely require it.
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Re: running electrical inside handlebars?
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Joined: Aug 2009
Posts: 558
Adjunct
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Adjunct
Joined: Aug 2009
Posts: 558 |
When I did mine I made a lot of rookie mistakes. I had a lot of splices in the same spot so it was hard as hell to pull through. I will drilled the holes too far from the pods. Well, I kinda had too cause I put my singles in the mirror holes. It looks better then running em on the outside but good look better. Would love to redo it but I'm lazy and don't want to buy new bars.
2008 Speedy, AI removed, DIY airbox destruction with K&N filters, spectres, re-jetted and "custom" rattle can paint job.
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Re: running electrical inside handlebars?
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Joined: Mar 2013
Posts: 231
Adjunct
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Adjunct
Joined: Mar 2013
Posts: 231 |
Quote:
thanks to the skill of SSjones, my stealth wiring is almost done
This is definitely on my to-do list. 
Opportunities multiply as they are seized. - Sun Tzu
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