Topic: Routing wires internally on Clubman handlebars.

[liaudio]

I carefully routed the wiring through my clubmans.  Looks 100 times cleaner than having them on the outside.  On my 76F, I notched the controls but really wished I had drilled the bars.  On my 75k, I drilled the bars.

I positioned the controls on the bars and marked where I had to drill.  Drilled a little hole for the position pin and a bigger hole for the wires.

Then I fitted the bars on the top clamp and marked where the wires should come out.  Then i drilled/filed a pretty big hole there.

I had a hard time just trying to get a pull string through the bars.  I eventually used a metal beaded pull string from a ceiling fan.

You'll have to cut off the outer loom covering the wires and pull each wire through individually. 

It'll make your life easier if you have electricians wire pulling lubricant.  (I'm a low-voltage electrician and had this already)

Tape a wire to the string and pull it through.

Only have like an inch sticking out and put vice grips on it to prevent it from pulling back.

Then, tape your next wire to the one you just pulled through and now pull that one through.  Again, only leave about an inch protruding.

Repeat these steps until all the wires have been pulled through.

As long as all the holes you drilled are big enough, it'll be easier than you think.


I wish I had some pictures of the procedure as I was doing it.

[nickjtc]

I had a hard time just trying to get a pull string through the bars.  I eventually used a metal beaded pull string from a ceiling fan.
It'll make your life easier if you have electricians wire pulling lubricant.  (I'm a low-voltage electrician and had this already)
Only have like an inch sticking out and put vice grips on it to prevent it from pulling back.
Then, tape your next wire to the one you just pulled through and now pull that one through.  Again, only leave about an inch protruding.

What is 'electricians wire pulling lubricant'?

Please clarify the 'tape your next wire to the one you just pulled through and now pull that one through' procedure. Doesn't this assume that you have at least double the length of wire than the amount hidden in the handlebars? Otherwise there won't be enough of the first wire to be able to pull the second wire through..and so on.

[Klark Kent]

my bar swap went smoothly with the wires all taped together and coated in WD-40.  i lassoed the ends in high-test fishing line and then tied a nut to the end of the line.  throw the nut in the end hole, let it come out the middle hole and then, pulling on the fishing line slowly rock the wire harness in and then back out a little, in and then back out a little (yes like sex)  before you know it you have worked your wire bundle all the way through. 

-KK

[nickjtc]

You both make it sound so easy. I envisage hours of travail, cursing and multiple beer consumptions....which will only make it all worse!!

[Klark Kent]

the in and back out a little does last about half an hour per side, but i wouldnt call it hard to do.  now drinking beer while you do it, that owuld be hard, unless you have a beer helmet.   

so for this procedure you will need
- new bars driled to accept both wires and control stay guide holes
- electrical tape
- fishing line
- 1/4" nut or similar
- WD-40 (less is more)
- beer helmet (more is more)

Happy Swapping
-KK

[liaudio]

You do essentially have double the length of wire.  The stock bars were longer so in stock form, the wires are pretty long. But the method of pulling them through using the last wire is tricky.  It only leaves you a few inches extra to untape the new wire once it's pulled through so inorder to get the most wire, you have to secure the end of it.  I used vice grips pinched to the male connector so it wouldn't pull back into the bar.

Electricians wire pulling lubricant can be found at Home Depot.  It's water based and wont harm the outer jacket of wiring.  WD40 or other petroleum based lubricants will.

[old750]

Has anyone routed throttle and clutch internally to have a totally clean look where you can't see any wires? I'm interested in doing this.

-Alex

[bill440cars]

Has anyone routed throttle and clutch internally to have a totally clean look where you can't see any wires? I'm interested in doing this.

-Alex

             Back in the 60's, I had a 58' 125 Jawa that had the throttle cable running through the handlebars and used a sliding piece that was actuated by a raised spiral shape that was on the inside of the throttle tube and the handlebats had a slot in them ( on the right side, of course) The throttle was very slow and clumsy. In my own opinion, I don't see how the throttle and clutch cables could be installed inside the bars and perform properly. If someone DOES have a way to do this, I'd like to hear it also.
                                                        Later on, Bill

[hopterfixer]

They make/sell internal throttles for the V-Twin based "chopper" crowd.  The are very similar to what Bill described but the ones I know of are weld on kits.  They do look pretty trick with no cables hanging out. 

[chung]

Wow pulling a chain is easier than pushing one

I have done more than a couple of these but never used a fish tape.
Most of the time the cover is hard as a rock so once I got the wires out of the old bars I cut it off.
You can't get all the terminals through the hole at once but the wires will go.
Then I just bend and push (about a hundred times)

BTW, beer makes everything better

[Uncleben89]

good post, I'll be doing this next week when my new handlebars come in.
I opted for more traditional bars, so hopefully I will have enough wire.

cheers

[malcolmgb]

my bar swap went smoothly with the wires all taped together and coated in WD-40.  i lassoed the ends in high-test fishing line and then tied a nut to the end of the line.  throw the nut in the end hole, let it come out the middle hole and then, pulling on the fishing line slowly rock the wire harness in and then back out a little, in and then back out a little (yes like sex)  before you know it you have worked your wire bundle all the way through. 

-KK

you use fishing line and WD-40 during sex     WOW!

[CBGBs]

I tried to run the cable through my Clubmans and got frustrated so exited them through the end of the control stalk. It worked very well. You never know what kind of sharp edged joint they may have left inside the bar and running wire down that 90 bend seemed like it would likely shred the wires or the shrink film. More power to you if you can do it.

[liaudio]

Well, it is cleaner looking.  As for the sharp edges...  I have been running it for about 3,000 miles with nary a problem.  The stock wires do seem to have a decent amount of insulation.

[Geeto67]

Well, it is cleaner looking.  As for the sharp edges...  I have been running it for about 3,000 miles with nary a problem.  The stock wires do seem to have a decent amount of insulation.

It will rub through eventually, just wait. It will probably happen when you are at that part of the LIE coming out of the city where there is no shoulder (like it did to me).

I glad you had a positive expirence with it so far but I have to say it is probably not the best way to runt he wires. Striaght up the bar and out the end (instead of down the U) is a much better way, plus if you use black convoluted tubing from there into the headlight it cleans up the look even more.

[Phil132]

Did/can anyone post photos? Thanks Phil