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9th February 2012
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Biker
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Join Date: Jan 2012
Location: Ohio
Posts: 27 Sportster/Buell Model: 883 Sportster Sportster/Buell Year: 2002 Sportster/Buell Model #2: Iron Head Sportster/Buell Year #2: 1983 Other Motorcycle Model: Road King Other Motorcycle Year: 1998
Reputation: 10
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Side mount brake light wiring
I attempted to run my side mount liscence plate brake light wiring through my swingarm. I drilled a hole in the swingarm and vacuumed a string through, but when I tried to pull a wire through it hung up.
Tried for an hour before admitting defeat. Damn plugs!
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Thank God, my daddy was a biker.
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9th February 2012
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Lord of the Flies
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Join Date: Oct 2008
Location: Northeast Philly
Posts: 1,011 Sportster/Buell Model: XLCH 1000 Sportster/Buell Year: 1975 Other Motorcycle Model: Fatboy Other Motorcycle Year: 1995
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did you try and pull one wire at a time?
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10th February 2012
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Biker
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Join Date: Jan 2012
Location: Ohio
Posts: 27 Sportster/Buell Model: 883 Sportster Sportster/Buell Year: 2002 Sportster/Buell Model #2: Iron Head Sportster/Buell Year #2: 1983 Other Motorcycle Model: Road King Other Motorcycle Year: 1998
Reputation: 10
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Yeah. I think there must have been a small hole that the thin string could get through, but the wire just couldn't make it.
I had the same problem when I tried to run wiring throug my handlebars. I could get a large gage wire through, but when I attempted to pull the wiring through it got hung up. I could probably manage to get them through one wire at a time but, after seeing a little marring on the wire I used to pull them through, I was afraid I would bite into my wiring, and eventually short out.
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12th February 2012
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Master Mechanic
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Join Date: Sep 2007
Posts: 255 Sportster/Buell Model: XLH Ironhead Sportster/Buell Year: 1974 Sportster/Buell Model #2: FLH 80 Shovelhead Sportster/Buell Year #2: 1981 Other Motorcycle Model: XLCH Ironhead (basket) Other Motorcycle Year: 1972
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You just gotta really debur your holes (I use a small grinding ball on my "dremel") and try greasing-up the wires.
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12th February 2012
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Biker
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Join Date: Jan 2012
Location: Ohio
Posts: 27 Sportster/Buell Model: 883 Sportster Sportster/Buell Year: 2002 Sportster/Buell Model #2: Iron Head Sportster/Buell Year #2: 1983 Other Motorcycle Model: Road King Other Motorcycle Year: 1998
Reputation: 10
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Quote:
Originally Posted by steve-o-
You just gotta really debur your holes (I use a small grinding ball on my "dremel") and try greasing-up the wires.
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If you're refeing to my handlebar problem, then the holes were pre-drilled. It's the weld inside the bar that I'm hanging up on. The bars are not one solid bent tube, they are mitered and welded. |
13th February 2012
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Master Mechanic
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Join Date: Sep 2007
Posts: 255 Sportster/Buell Model: XLH Ironhead Sportster/Buell Year: 1974 Sportster/Buell Model #2: FLH 80 Shovelhead Sportster/Buell Year #2: 1981 Other Motorcycle Model: XLCH Ironhead (basket) Other Motorcycle Year: 1972
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Didn't realize you were hangin'-up on welds. I've just seen too many scarred-up wires from nasty lookin' holes.
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19th February 2012
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Biker
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Join Date: Jan 2012
Location: Ohio
Posts: 27 Sportster/Buell Model: 883 Sportster Sportster/Buell Year: 2002 Sportster/Buell Model #2: Iron Head Sportster/Buell Year #2: 1983 Other Motorcycle Model: Road King Other Motorcycle Year: 1998
Reputation: 10
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Good news!
Last night I managed to get my hand controls wires through the handlebars. It took about two hours because in order to stagger the wires to make the lead as thin as possible I had to cut the wires by the controls and solder them back together.
What a relief though. I have put a ton of hours on this bike so far, on this winter makeover, and if I had to have wires hanging it would have ruined the entire project. I contemplated on removing the controls all together and mounting a switch box somewhere, but last year I tried that and failed miserably - to the point of having to buy a new wiring harness.
Now that the wiring is all done, it's off to the next challenge. Molding the rear fender. Uhg!
Last edited by jlongbrake; 19th February 2012 at 16:43..
Reason: misspelled word
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