Topic: 1974 CB550 External wire routing possible?

[luke000]

I have a 74 550 I am swapping out the stock bars with some clubmans.  The stock bars had the wires run internally the bars I got today are not.  I currently have both handlebar switches disassembled FWIW for polishing.  I was wondering if there was a way I could run the wires externally (possibly putting in an access port in the housing??), or will I have to drill some holes in the new bars    ; would drilling holes in the bars make them structurally unsafe?  Thanks in advance.

[luap]

you can drill the new set of bars one at center of bar clamps an one at each end, be careful pulling the wires though dont cut the coating

[IndyFour]

You can do as luap suggested and drill holes in the bars or run them externally...that's what I chose to do when I put on drag bars a couple years ago.  Using a dremel or an angle grinder, you can cut a notch in the bottom half of the controls so that the wires will pass through without pinching.  I recently switched the drag bars out for clubmans and kept the wires running externally....it doesn't bother me, but I know others like the clean look of internal wires.  To clean it up a bit, I slipped some black plastic corrugated wire looming over the cables since the black insulation on the original wires was looking a bit shabby.

If you end up cutting notches, be aware that your cutting/grinding can put tiny metal shavings into your switches (not good), so take care to protect the "innards" of your controls when you are doing the job.

If you want pics of what mine looks like, I'd be happy to share.

[andrewk]

you can drill holes to run wires internally without compromising the bars integrity, but you should know that fishing wires through clubman bars is a PITA.  I've done it, and would do it again if it were on my bike, but I would complain alot and if you don't care it might not be worth the effort.

[luke000]

You can do as luap suggested and drill holes in the bars or run them externally...that's what I chose to do when I put on drag bars a couple years ago.  Using a dremel or an angle grinder, you can cut a notch in the bottom half of the controls so that the wires will pass through without pinching.  I recently switched the drag bars out for clubmans and kept the wires running externally....it doesn't bother me, but I know others like the clean look of internal wires.  To clean it up a bit, I slipped some black plastic corrugated wire looming over the cables since the black insulation on the original wires was looking a bit shabby.

If you end up cutting notches, be aware that your cutting/grinding can put tiny metal shavings into your switches (not good), so take care to protect the "innards" of your controls when you are doing the job.

If you want pics of what mine looks like, I'd be happy to share.

Could you show me some pictures of your switches with the notches cut out?  I think I will try that out tomorrow.  Right now there are no electronics in the housings so I am not worried about messing up the electronics with metal shavings.  I still need to polish them so they will be very clean before they are put together. 

[IndyFour]

Here you go.  Kind of hard to tell once they're on the bike and assembled....but you just cut a notch big enough allow the wires to pass through without being pinched.  Just make sure that there are no sharp edges and you should be good.  The other issue is that your MC can't go right up next to your right hand control, but that's not really a big deal.








Hope that helps.  I saw your build thread....great job on the polishing!  Hey if you are in need of a right side cover, I have one that i'll donate to your cause.  It has the top right corner broken off, but otherwise in o.k. shape.  I'll never use it.  Glad to see a young guy working on a project like this.