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  #1  
Old 11th October 2010
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Default Cutting holes in place of stock dimples (biltwell keystones)

Hey all, I couldn't find information on this so I'd like to ask which method would be better/safer/easier.
I tried to internally wire my 1" keystone handlebars with a lot of blood & sweat. Once I finally was able to get the wires through one side, 2 of the 8 wires had no continuity. I decided it probably wasn't a good idea to cut my harness with my bike still under warranty.
My idea is to cut rectangular holes where there would normally be dimples so the stock harness can slip through. But I don't want to compromise the structural integrity of the bars. Do you think it would be dangerous?
The other option would be to mill a slot out of the control modules so they can sneak out from between the bars and the controls.

Whataya think? Am I nuts?
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Old 12th October 2010
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I drilled holes at the dimples in my bars. I disassembled the plug & slid each wire through by itself them put it back together. I have a 2003, everything was color coded and the plug was easy to slip apart. I think I used a pick & small flat screwdriver.
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Old 12th October 2010
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Yep .. me too. Drilled through the the dimples to run the wires through the bars. Make sure the holes are big enough and smooth out the sharp edges. Structurally, you will be fine. Warranty wise, I cannot comment.
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Old 12th October 2010
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I have drilled 3/8" holes, then deburred the edges with a dremel. No need to cut any wires. Connectors can be removed from wires without damaging them.
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Old 12th October 2010
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My NASH bars have drilled holes in lieu of dimples...I think you should be fine assuming ur not a gorilla and have serious road rage issues...
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Old 12th October 2010
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You as well as other posters are drilling in the dimples, does anyone know if you can drill bars that don't have dimples?
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Old 12th October 2010
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Quote:
Originally Posted by Halcyon1 View Post
You as well as other posters are drilling in the dimples, does anyone know if you can drill bars that don't have dimples?
yes sir ...

I ran mine through the dimples under the hand controls and through a straight hole inside the risers.

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