Topic: How Does This Cable Get Routed When There's No Holes in the New Handlebar?

[Imago]

Please take a look at the photo and provide suggestions on how to route this large cable without drilling holes in my new Euro handlebar. For the life of me I can't figure out how to clamp the part to the handlebar without crushing this cable.

I'm sure many of you have faced this same issue and there's a common solution. Pictures of your setup would be great!

 

[BomberMann650]

If you don't want to modify the handlebar, you then have to modify the bar controls.
I used a dremel and made the wiring "U" relief much larger.  Then it could clamp down.
Still punched a hole into the handlebar for the nub in the controls.

[Imago]

If you don't want to modify the handlebar, you then have to modify the bar controls.
I used a dremel and made the wiring "U" relief much larger.  Then it could clamp down.
Still punched a hole into the handlebar for the nub in the controls.

Will it still clamp tightly onto the handlebar? And/or is it the nub that keeps it from turning?

Anyone have photos?

[Scott S]

 You have to remove that nub inside the controls, too. Or drill a hole for it. They stay clamped tight without it.

[Gordon]

You have to remove that nub inside the controls, too. Or drill a hole for it. They stay clamped tight without it.

Agreed.  I removed the locating pin on both of mine years ago, and I've never had any problem with the controls rotating on their own. 

[atm cycles]

Much nicer job is to drill the holes. I use a step drill. measure from end of bar to holes. Transfer to new bar.  Drill 3 overlapping holes then file smooth. Drill the pin hole. Tape ends of wires together. I use soapy water in a spray bottle for lubrication. Push and pull wires through. You'll be happier with a nice clean look

[Imago]

Much nicer job is to drill the holes. I use a step drill. measure from end of bar to holes. Transfer to new bar.  Drill 3 overlapping holes then file smooth. Drill the pin hole. Tape ends of wires together. I use soapy water in a spray bottle for lubrication. Push and pull wires through. You'll be happier with a nice clean look

I was worried that my drilling might affect the integrity of the bar, although I suppose the OEM's are drilled and are unaffected. Thoughts?

[BomberMann650]

The wiring holes are not big enough, or close enough together to cause a problem.

My superbike bars are black, the wiring sleeve is black, I hardly notice it

[RedLiner]

I didn't like how Honda had the wires going through the bars making it a pita to run the wires through them. My solution was to drill an appropriately sized hole in the bottom of the switch housing.



I'm also running clipons and thought it wouldn't look good with the wires coming out of the end.

[Imago]

You have to remove that nub inside the controls, too. Or drill a hole for it. They stay clamped tight without it.

Got it... what's the best way to remove the nub? Does it unscrew or is it press fitted?

[Don R]

 It's pressed in, a good set of pliers will pull it. My K0 was missing the pin and it rotates a little. Most that do it say it won't. Keep the pin just in case.

[78whiteorbs]

I didn't like how Honda had the wires going through the bars making it a pita to run the wires through them. My solution was to drill an appropriately sized hole in the bottom of the switch housing.



I'm also running clipons and thought it wouldn't look good with the wires coming out of the end.

Agreed- change most yammie bars in 5 mins as the wires.  are for a majority outside the bars and notched at the pods.
Makes changing bars a breeze...thats one thing I would have prefered to have on the the 550/500 though it is a beautiful bike and you cant have it all as they say...I loath running wires or notching stock pods to run em outside. Sure its easy enough but just agravating. Rant over-