Topic: Clubman Bar Help Needed ASAP

[rockwell500k]

hello all,

i've been trying to install these bars on my 71 cb500 for a few days (in my spare time) and finally have come to a dead stop.

the bars were not pre-cut/drilled for the wires, so i carefully cut and smoothed holes for the wires to pass through. i even removed the dowels in he controls to mount on the bars...

now, i CANNOT for the life of my run the wires inside. i have tried just about everything. the angle is just too difficult to overcome...

can anyone suggest anything?

i have fruitlessly searched...and come up with nothing. sometimes keyword searches suck.

any help would be appreciated...some sneaky tips, or even another method.

thank you very much!

[andy750]

I didnt bother running wires through my cafe bars - the angle was too steep  It can be done Im sure but as your finding out its a whole lot of hassle.

Here is how mine look...




Good luck
Andy

[Shenanigans]

Where did you drill your "exit" holes?

If you drill the exit hole out just a little bit, say an inch, to the inside of the controls (on the bars) routing the wires should be pretty easy with no angles to overcome. Get what I am saying? If not I could bust out the MS paint.



Hey andy, where did you get those clubmans anyways? They look a lot wider than the ones I see everywhere and I like them.

[rockwell500k]

i guess several months ago i made a thread when i first purchased them...

i since forgot, and it came up on another search (weird) and someone provided a nice link.

and i put the holes in the almost exact location as the stock ones...(modified for the new bars of course)

i think i may try putting them before the kink so it exits towards the tree opposed to below like i originally had planned.

thanks for the quick replies and photographs!

[andy750]

Hey andy, where did you get those clubmans anyways? They look a lot wider than the ones I see everywhere and I like them.

Thats because these are NOT clubmans (which are way to sever an angle for my wrists) - these are tomesselli ..very comfy...will be going on a 5hr ride to Maine on this bike this coming weekend and apart from the hard seat it will be fine with these bars....great for corners 







cheers
Andy

[SD750F]

Most clubman or similar bars will use "three" pieces of tubing! One for the center section and then the other two for the bar ends. Using this construction you will have the parts but welded and you will not be able to pass wires inside...

Scott

[MCRider]

To Rockwell, I've always notched the bottom of the switch and let the wires run under the bars. With Clubman's not much chouce. Sorry you put so much effort into it.

To Andy: I think "clubman" is just a generic noun describing that look of bar. Like Drag Bar, or Ape Hangers, or flat trackers. Tommaselli is just one manufacturer of clubman styled bars, and they have their own design. Which is more to the point, where did you get them? I prefer that design where the clipon portion goes past the "U" portion, rather than the mitered joint. But that makes them pricier too I think. I've searched for Tommasellu bars and can't find them.

[karmasic]

funny, i JUST did this on saturday. and i was on the verg of tears. but then i got it. i figured out a way to get it every time. its just that corner right? i made a lasso with a wire hanger, slid that in the bars all the way to the corner. then slid the wire ends to the corner. the wire ends should go through the loop in the hanger. once you have both pieces at the corner of the bar, you should be able to pull the hanger, which will grab the end of the wire and get them through the corner. spent 3 hours on the first side and 3 minutes on the second side of my bars. hope that helps.

[Dunstall_74]

There is a few threads on this.  I used a guitar string to pull my wires through.  Worked well.  Of coarse, I was pulling wire looms on NOS switches that are a bit more nimble than crusty old ones.  Check this out  http://forums.sohc4.net/index.php?topic=10660.msg109530#msg109530

[Shenanigans]

Hey andy if you pass anywhere near syracuse let me know. I am always looking for an excuse to get some riding done around here.

[andy750]

Hey andy if you pass anywhere near syracuse let me know. I am always looking for an excuse to get some riding done around here.

I certainly will! I was in the Adirondacks at the end of June for a week of blissful, traffic-free riding - wow great roads!!

Ron - I got the bars in Germany from a friend.


Cheers
Andy

[rockwell500k]

well...i just went the "simple route" and put a nice rounded hole directly at the bars end.

i did not want to route the wires outside the bar...and i found that having them coming out where i did actually works quite nicely. the leads go right back into the headlight bucket, so it works well.

here's a crude iphone photo to give a visual.

[MCRider]

Hey andy if you pass anywhere near syracuse let me know. I am always looking for an excuse to get some riding done around here.

I certainly will! I was in the Adirondacks at the end of June for a week of blissful, traffic-free riding - wow great roads!!

Ron - I got the bars in Germany from a friend.


Cheers
Andy

That 'splains it. I'm not really ready for them yet, next project. Maybe by the time I am they will be available stateside. Nice find.

[MCRider]

well...i just went the "simple route" and put a nice rounded hole directly at the bars end.

i did not want to route the wires outside the bar...and i found that having them coming out where i did actually works quite nicely. the leads go right back into the headlight bucket, so it works well.

here's a crude iphone photo to give a visual.


Good photo and good result.