how do i thread my electrical wires through the clubman handlebars for my vintage motorcyle?

Question

these handlebars have over a 90 degree bend. i need the group of wires to be able to manuever the bend

Answer 1

Get a piece of 14 gauge stranded and poke it thru the bars till you manage to grab it at the other end. Make a loop in that wire and tape it solidly with electrical tape about 1.5 inches down. Take the harness you are running thru the bars and take one of its wires thru the loop in and do the same with the tape. Tape the other wires in a staggered fashion....I.E. tape one wire to the first about 1 inch down form the loop. Tape every wire suceedingly down one inch from the last one you taped. Make sure you cover the ends of the wires when taping. This will help to keep them from snagging. Once all the wires are thru you can untape them and pull the slack out of any loose wires. If 14 guage doesnt cut it try 12.

Answer 2

Dont thread it through the 90+degree bend. fit a grommet to the straight end and pass wires out under instruments. The sharp edge cuts through wires after a few months riding. May not look as clean or 'cool', but more practical and lasts longer.

Answer 3

Take off the connections. Wrap the wires tight with tape. Run a line through the bars and fix it to the end ot the wires (tape). Pull the line while pushing the wires with a coathanger, etc.

I had trouble pulling wire through dimpled bars. You may want to consider that.

Answer 4

A stiff wire might be hard to get through that bend. I usually take a piece of string and use an air gun to blow it through the tube first. Then you can tie a piece of wire to that and pull that trough.Use something flexable like mechanics wire or even some copper wire to make it easier on you.

Answer 5

Wrap them around an opened wire clothes hanger,push them through