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Old 12-25-2012, 03:48 PM   #1
DSMRossi
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Can't snake wires through bars?

I have an 03 A.

My Ma bought me some Heat Demons for Xmas, and for some reason I can't snake the harness through the bars. The kit even comes with a thin plastic snake to make short work of it, but it keeps binding up near the speedo assembly. Anybody know what could be up? Is there any other wiring in the bars I don't know about?
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Old 12-25-2012, 05:55 PM   #2
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Wiring in the bars is not standard on the A models unless u drill a hole in them yourself or have set of bars that are predrilled. That being said, I usually use a piece of wire like speaker wire. Thread it thru first, tape the wire that I want to pull thru to the wire, then pull it all back thru. Done it at least a dozen times and works well.


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Old 12-25-2012, 08:17 PM   #3
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You can also use a shop vac on one end and a piece of string. Suck the string through the bars then tie or tape onto the wires and pull them back thru. That is what I did on my '03 for my heated grips. - Jim
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Old 12-25-2012, 08:26 PM   #4
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It was that last bend that it kept getting caught on. What I was able to do was pull the small clip that holds the harness to the bar out. In the hole the clip was in, I was able to feed 2 pieces of wire through that little hole, one going to each bar end. Then I soldered the 2 pieces of wire together and stuck them in the hole.

Speaker wire may have worked being soft like it is. Thanks guys
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Old 12-25-2012, 09:08 PM   #5
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I hope the hole has no burrs...
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Old 12-26-2012, 03:44 AM   #6
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Grease it all up good with pulling grease.


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Old 12-26-2012, 05:46 PM   #7
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WD40?? should have worked good?
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Old 12-27-2012, 03:43 AM   #8
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WD40?? should have worked good?
Not the same at all.
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Old 12-27-2012, 04:57 AM   #9
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Hhmmmmm, I wonder why it wouldnt have worked? Never had to do this so I am just thinking out loud. But I would have also tried the wire and taped the other wires to it aswell.
Glad you got it figured out.
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Old 12-27-2012, 06:26 AM   #10
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We had the same issue but it was with the wires making a sharp turn. We we were able to solve this by using a different heat shrink. Be careful of using WD40 as a lube on the wires. WD40 contains petroleum which will break down many rubber products over time. It is absolute death on o-rings.
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Old 12-27-2012, 12:49 PM   #11
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It was the very last bend. After you clear the clamshell, you pass through that low bend and it pushes the wire towards the apex of the final bend. It was a pain in the ass. Just feed both ends of a long wire through the hole the harness clips into. Then push it towards both ends and poke the loop you're left with into the hole. No lube needed.
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Old 12-27-2012, 02:34 PM   #12
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Quote:
Originally Posted by TooRad4u View Post
You can also use a shop vac on one end and a piece of string. Suck the string through the bars then tie or tape onto the wires and pull them back thru. That is what I did on my '03 for my heated grips. - Jim
That's the way I did it. Worked well. You may also use some wire lube which you can get at home depot to reduce the friction when pulling the wires through.
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Old 12-29-2012, 01:00 PM   #13
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You know you can pull that plastic harness clip out before you start?


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