Topic: Handlebar Wiring Clubmans K4

[kmenzel]

How in the %$&% do you get the wires through the clubmans turn.  I tried for a while and have pretrty much give up.  I am going to think about other switches unless someone has a great idea? 

[mrblasty]

You will meed to fish a thin piece wire from hole to hole. tie a strong piece of string to the end of the wire and pull it through the bars, tie the wiring  to the string and pull through. run the string through both handle bars first and do this with the bars off the bike.
Good luck.

[paulages]

i drilled holes right at the kink, and just dropped the wires out there. it puts them straight towards the triple tree where they want to be aynway. i can take a picture if you need.

[kmenzel]

I did try the wire and i was able to fish a small wire through.  But, i couldnt get all the wires around the bend.  its a lot on the left side

[hymodyne]

I don't have clubmans but i shortened my stock 500 bars down to 4 inches. I took a steel fishing leader and bent the hook flat around the two or three  longest of the wires going through the bars.I taped these and the rest tight, greased them with axle grease and pushed through until I could see the wire leader at the center hole. when I could, I got a pair of pliers on it and pulled the rest of the wire slowly through.

hym

[MikeDeB]

I route the wires outside of the handlebars by notching the bottom of the switchgear housing.  I've done this on two 750's and works just fine (eliminates the need to fish the wires through the bars).  The switchgear housing can be notched using a Dremel tool and circular stone or cutter.  Use eye protection when doing this.  Don't use this procedure if you're doing a restoration. 

[KB02]

I don't have clubmans but i shortened my stock 500 bars down to 4 inches. I took a steel fishing leader and bent the hook flat around the two or three  longest of the wires going through the bars.I taped these and the rest tight, greased them with axle grease and pushed through until I could see the wire leader at the center hole. when I could, I got a pair of pliers on it and pulled the rest of the wire slowly through.
hym

That's going to be the trick that saves you if you;re going to pull them through the bars

[justfours]

try to get the wires as small as possible. if te wires cross over eachother inside the tape it will make the whole bundle thicker. On mine I used an older 750 left control with no HI/LO switch, making it only four wires. REtaped straight and tight. use plenty of lube. also dont forget to deburr holes really well.

[pablo78cb550]

man i can't believe no one said to try it this way:
ok, get a length of string and an air hose or a good set of lungs.
tape/close up both ends of the bars, and the opposing side wire hole. leave the port that the wires are going to come out of open.
stuff the string into the hole that the wires are going to go inside of.
blow air through the bars at that hole.
the air has no where else to go but out. and guess where the string is going to come out of?
the hole you need the wires to come out of!!
ok, tie the string aroud the wires and pull them though.
ta da!!!!

[Raul CB750K1]

Have you tried a brake cable? (a bicicle brake cable or gear shift cable -thinner- could do too)

Also, lots of grease. dishwashing liquids helps a lot when it comes to insert cables in wall conducts, don't ask me how I know.


Raul

[crazypj]

With clubman bars its much easier to fit wires straight out the end and fit grommets to stop water getting in. I've never seen anyone fit wiring through the centre section (maybe the bars I fitted were made different, there wasnt a hole from centre to the outer?)
PJ