Topic: Drilling Renthal alloy bars to run wires?

[pjwalsh]

I'm going to be swapping my bars over to the Renthal alloy bars in a couple of days but I'm trying to decide if I run the wiring inside or out. I want to run it on the inside but that means drilling the bars.

Will drilling the bars to run the wires internally weeken them at all?

[CafeDawg]

I've drilled two sets and don't believe the structural integrity has been compromised.  It looks much cleaner and means you don't have to alter switches.  Remember they came stock with holes in the bars and don't think putting three holes in them is going to make them dangerous but yes literally speaking it will weaken them. 

Respect
CD

[pjwalsh]

Thanks CD, looks like I'll be running the wiring internally!

[mrrch]

The wall thickness is thicker so check that first before drilling. The wire may not fit inside anyway.

[CafeDawg]

I should have added that my bars were not Renthal's so I would check them for fitment as mrrch suggests.

CD

[bert96]

The wall thickness is thicker so check that first before drilling. The wire may not fit inside anyway.

It's tight but it fit,i did the same job.

Bert

[pjwalsh]

Hey Bert, did you do it with the renthals, reason I'm asking is the bars being alloy I'm not sure if they are any different than the standard ones being a chromed steel?

And where's the rest of the vid in your sig? That's mesmerising!

[pjwalsh]

And did you use anything in particular to lube the inside of the bars to make it easier to slide the wiring through?

[CafeDawg]

I tied a piece of string to a coat hanger to run the line in and then the string to pull the wires through, lubed with simple green I think. 

CD

[pjwalsh]

I'm in the process of fitting the new bars to the bike, it hasn't been a fun job!
In the process of pulling it apart I found that someone else had already attacked and butchered the wiring loom so it had to be cut to just get it out through the old bars.

Any how after all that, I did get the loom through. But after hooking up my throttle cables I have a very sticky throttle, it won't release by its self!

I had to leave it due to a half drunk frisky wife and a hungry baby daughter needing my assistance. I would like to know what I could possibly do to remidy this, it has stock length cables now but will be wanting to go to a shortened length cable later. I've gone from stock bars to the ultra low Renthal bars so approximately 3" more cable to play with!

Please help!!

[bert96]

Hey Bert, did you do it with the renthals, reason I'm asking is the bars being alloy I'm not sure if they are any different than the standard ones being a chromed steel?

And where's the rest of the vid in your sig? That's mesmerising!

Yes,my bar is in alloy too and i use drill bits very similar to these one,
http://www.ebay.com/itm/10PCS-Hard-tungsten-steel-alloy-rotary-file-Grinding-Nail-Drill-Bits-with-Wear-/220925377945?pt=LH_DefaultDomain_0&hash=item33702dbd99

...and a little bit of cutting fluid and voilà!

If you can find the rest of the video let me know

Bert

[Fritz]

Any how after all that, I did get the loom through. But after hooking up my throttle cables I have a very sticky throttle, it won't release by its self!

Most likely, you'd need to change the cable routing. They don't like sharp bends. Honda's workshop manual shows the proper routing and yes, maybe the lower bars require to shorten the cables in order to get the routing right.

[pjwalsh]

Damn why didn't I think of getting bits like those, it would have made the job so much easier and neater! It was a bit of a hack job with what I had but its done. I'll be buying those bits for the next time I do it!

[pjwalsh]

I just got the bike back together but the cables are too long I think. The throttle is sticking and the clutch is slipping really badly, please help me!

[pjwalsh]

Clutch is good, just the throttle to sort out. I think it's just the length and possibly the age of them doesn't help either. I'll get some shorter ones made up and see how I go.

[srbakker]

You lubed the bejeezus out of it?