Wiring in handlebars

[IronButt70]

I'm trying to swap out the handlebars on my 2017 FLSTC. I cant' get the plugs to pass through the holes on the grip end to get the harnesses out. Is there some trick to this? Looks like the hole just aren't big enough.

[Garry in AZ]

You usually have to de-pin the plugs and then re-pin them after running the wires through the new bars.

[IronButt70]

You usually have to de-pin the plugs and then re-pin them after running the wires through the new bars.

Thanks. Now I have to a tool to do that.

[Billy]

If they are the original bars, the plugs should pass through the holes in the bars with a little finesse.

[IronButt70]

If they are the original bars, the plugs should pass through the holes in the bars with a little finesse.

They are the originals. Guess I don't have any finesse. Tried several times to get them out and all I managed to do was partially mangle one of the plugs. 

[Pirsch Fire Wagon]

Little spray silicone helps immensely to remove and install.

[IronButt70]

Little spray silicone helps immensely to remove and install.

Tried that. No luck. Did manage to skin the insulation off one of the wires. 

[Langwilliams]

I dropped a ceiling fan chain through the bars with a long shoe string tied to it. I taped the wires to the shoestring an used it to pull them through no problem. the chain just added the weight to get the string through but the chain has too much resistance to pull the wires through.

[IronButt70]

I dropped a ceiling fan chain through the bars with a long shoe string tied to it. I taped the wires to the shoestring an used it to pull them through no problem. the chain just added the weight to get the string through but the chain has too much resistance to pull the wires through.

With or without the plugs on the wires. Once I depinned them the wires came out easily.

[Hossamania]

I feel your pain on the plugs and trying to pull them out without depinning them to save time. I have found that skipping a step to save time rarely does.
Good job on getting it done.
For any body doing bars, or any fishing of wires in the future, Klein makes a spray lube that looks like shaving cream, silicone based, that works like a dream. Comes with a long spray tube that you can insert to lube the bar or conduit well into the opening, leaves a dry film of silicone on the wires after install, doesn't gum up like traditional lubes do, doesn't stain. Works very well for those cool looking bars with the sharp bends in them that are nearly impossible to get a bundle of wires through.

[IronButt70]

 

I feel your pain on the plugs and trying to pull them out without depinning them to save time. I have found that skipping a step to save time rarely does.
Good job on getting it done.
For any body doing bars, or any fishing of wires in the future, Klein makes a spray lube that looks like shaving cream, silicone based, that works like a dream. Comes with a long spray tube that you can insert to lube the bar or conduit well into the opening, leaves a dry film of silicone on the wires after install, doesn't gum up like traditional lubes do, doesn't stain. Works very well for those cool looking bars with the sharp bends in them that are nearly impossible to get a bundle of wires through.

Thanks Hoss. Found a local store that carries it.