Topic: changing handlebars, wiring, my brain......problem!

[Slim_SLC]

so, removing the wiring from the stock handlebars took me over 2 hours of spraying WD40 and pulling/pushing....this was due to a generous application of electrical tape by the former owner.  Anyway, trying to hook the throttle cables back up to the throttle tube and the brittle plastic broke when one of the cables dropped into the slot......so now I need a new throttle tube........dang it.  Anyone know where to get this part?  Is it likely that I could find this at a bike junkyard?

also, I am trying to dremel out the switch housing to enable running the wiring externally on the new bars and I think I chopped away too much of the housing, and I still can't fit the wiring bundle on the clutch side.  Now what!?

[GroovieGhoulie]

How did it break?  My throttle tube broke one the outside "ear" that holds the push cable end.  I searched the ground for 10 minutes, found it, then super-glued it into place using a tiny bit of super-glue. 

Still holding to this day.

ETA: You can still get the throttle tubes from Honda.  Get the part number from an online fiche like http://www.crotchrocket.com and order it.

[Slim_SLC]

yeah, that's the same place mine broke....the little ear thing that retains the ball end of the throttle cable...I wasn't able to find the plastic piece that broke off, but maybe I can fab something that will work.  thanks.

[bryanj]

still available and not too expensive from Honda

[nippon]

@Slim_SLC

Do not dremel your switch housings! Believe me, it's no problem to put the cables back in
the handlebar.
You have to remove the old cable housing completely. Then you have to take a new housing for your cables.
The best is a heatshrink tube ( think, it's called so) which fits and protects your cable perfectly when you make it warm
with a hairdryer or anything else.
http://cgi.ebay.com/15-HEAT-SHRINK-TUBING-1-4-3-16-1-8-BLACK-tube-3M_W0QQitemZ320008930533QQihZ011QQcategoryZ100181QQrdZ1QQcmdZViewItem
Make the new heatshrink tube housing two inches longer as your cables are. Then you have to mount a long
cord or a lite wire to the end of the new cable housing, on the other side of the cord you have to mount
a liitle screw (-mother) (heavy enough) or anything else.
Let the screw fall into your handlebar
until you reach the hole in the middle of the handlebar.
Take a a pincer to pull out the cord of the hole. Hold it.
Cut the cord that the screw can fall out on the other side of the handlebar.
Pull the cable housing to the right position.
Last, cut the housing to the right cable lenght.
That's all.

nippon

[Slim_SLC]

yeah, the problem is I don't have a hole in the new bars for the wiring, and I don't want to drill them, for one, because I don't have a vice or drill press, and two, because I don't want to weaken the new bars by drilling a hole in the middle.  My understanding is that the stock honda bars are reinforced around the holes to add strength that is lost in drilling them out. 

so, anyway, not dremeling is already out of the question because I've already done it.  So, now, I guess I need to find a solution to getting the wiring to fit out through my dremel hole and then finding a way to seal the hole so water doesn't get in there.  First I guess I need to order a new throttle tube from honda.  Anyone happen to have a part number?  I tried that online fische thing and couldn't find it, although it's probably because I don't know how to use it. 

[turnenwheels]

What type of bars are you changing to...You may want to consider re-wiring the kill, lights and starter button off the bars, it will clean them up and give you a chance to get to know your wiring.  Myself and Chippyfivefifty have rewired verything off the bars.  Our set-up is gives a clean and oldschool look.

[puppytrax]

Anyone happen to have a part number?

Pipe, Throttle grip  53141-300-010 $9.80 is the one I have on order. 

[Slim_SLC]

What type of bars are you changing to...You may want to consider re-wiring the kill, lights and starter button off the bars, it will clean them up and give you a chance to get to know your wiring.  Myself and Chippyfivefifty have rewired verything off the bars.  Our set-up is gives a clean and oldschool look.

do you have pics?  I can't even picture this.   sounds cool though.  The bars I got are just euro bars, non drilled.  I also bought clubman so I could check them out, but without rearsets it was too radical. 


oh, and thanks for the p# puppytrax!