Topic: Change of handlebars

[Clive Halls]

My USA import has high bars which don’t suit. When I change them how is the best method of removing the through the bars wiring ? That is from the headlight end or the switch end. My new bars are not drilled so I will re route on the outside.

[BenelliSEI]

Clive....... I’ve found the best way is to open up the switch (split the halves). Undo all the connections in the head light. Then pull the wire bundles back, out of the head light, through the bars and off the bike. Don’t disconnect anything at the switch. The problem will be the outer black plastic wrap is totally crisp after all these years. It won’t come back through the bars easily, and you will likely destroy the sheathing. Apply some grease our wire lube to them, before pulling them into the bars.

In order to route the wires outside the bars, you will have to cut a notch in the switch housing. I use a Dremel tool with small milling attachment. You’ll probably have to re wrap it the wire runs with tape, shrink wrap or vinyl tubing......

[Clive Halls]

Thank you that sounds a sensible way to attack the job. The outer casing is indeed a bit hardened so I will re do it.

[PeWe]

You can find lower bars with holes for wiring. It looks mint on a stock CB750. .

My CB750 K2 has a lower that is  rather comfortable.

http://forums.sohc4.net/index.php/topic,168243.msg2093754.html#msg2093754

Pictures in the end if that thread if you enter the first page. April 2019 has a series of photos too.

[Scott S]

 Tape up the bullet ends with painters tape. Shape the bundle into sort of a point. It keeps the bullets or connectors from snagging inside the bar and makes it easier to feed through the new bars.It helps to have a second set of hands, too.
 If the shrink wrap around the wire is dry, cracked and brittle, trim off those sections with scissors and re-tape with electrical tape.

[PeWe]

+1  tape
Tape the connectors and shape it thin for easy access thru the holes.
It can be s good idea to replace the old dry sleeving.

[BenelliSEI]

Assuming you decide to use drilled bars, visit any good electrical supply house and ask for a small container of “wire pulling paste”. It’s used for pulling large cable bundles through conduit.  If you know any electricians, just ask for a bit in an old coffee cup. On job sites, they use it by the gallon....... it really works and make the job easier.

[carnivorous chicken]

Lube. Spray lube into the bars before you start pulling the wiring through. And lube the wiring when you want to pull it into the new bars. You can tie a string to the wiring with a screw tied to the end and drop it through to route the wiring in the new bars.

[pjlogue]

When pulling the wires out of the bars be very careful that you don't shear the wire by scraping against the sharp inside edge of the hole in the bar.  The holes are usually stamped and the inside edge will ruin your wire insulation if you just try and pull the wire out (or in) .

If you go to put wires back in the old bars or new bars I would take a Dremel and bevel the inside edges of all the holes where the wires pass through before pulling the wires.  You can take some string and suck it through the bar with a vacuum and use it to pull the wire bundle through.  Wire pulling lube helps. 

-P.

[Bankerdanny]

I use a metal hanger from the dry cleaners. Cut and straighten the hanger and feed it through the center out to the hole at the grip. Bend a small hook at the end and then tape the control wires to the hanger. Lube up the wire casing (I just use lithium grease) and carefully pull the wires through the bar. Watch the casing carefully where it enters near the grip because it will sometimes snag on the hole.