Topic: How do you wire clubman bars???

[speedknot]

Im in the process of fitting clubman bars to my CB400F.  I need some ideas on how to wire the bars up.  I know that its not an option to run the wire throughout the whole bar.  Especially at that angle.  For those who have done this setup, could you send pics or give me some idea on how this could be done? 

[Inkscars]

I've heard tales of people running wires on the inside the bars. Most applications require drilling, zipties, hangers and patience. 
I have all but the latter.
Mine run on the outside, and considering that I just slapped em on there, I don't feel that it is messy or tangled. I don't know if you've met Mr. Zip Tie (phd). You two will not only be introduced, but I see a great friendship in your future.

[JS550]

Mine run outside the bars too. They come out the bottom of the control then ziptie @ the bend. You headlight hides the rest because the bars are so low.

[speedknot]

Did you guys have to notch the handlebar control housing to run the wire on the outside of the bar?

[JS550]

Yes, & mine is a 750. Wouldn't think yours would be too different though? Here are a few pics. One of my controls actually had the wires coming out of the bottom already, but I had to notch the other.
jim

[Inkscars]

No modification at all on my end, other than removing excess throttle tube (1/4-1/2")
and removing stupid high rise brackets. *vomits*

[Quorthon]

I just finished running my wires through the clubmans on my cb500.

You need to drill and dremel the wiring holes out at the controls and center of the bars.

Tie a bolt to some twine and drop it into the control hole and pull it out of the center hole.

Tie the twine to the end of the wire, Grease the heck out of the wiring and pull/push it through!

It helps to have someone else there to pull as you push, which takes the tension off of the sharp bend.

Not easy, but not impossible either, and definitely makes everything cleaner.

Good luck!!

[Joel]

My CB400F has notches on the controls to run the wires outside the bars.  I know my RH control has been changed but the LH looks stock to me.

[Dave-and-his-550]

Yes, & mine is a 750. Wouldn't think yours would be too different though? Here are a few pics. One of my controls actually had the wires coming out of the bottom already, but I had to notch the other.
jim

Must be fun fillin up that brake fluid reservoir on those clubmans...

I'm thinking of ordering club man bars for my 550, so on a scale of 1-10, 10 being most difficult, how hard are they to install? I have never removed my handle bars so I'm not sure what wiring you guys are talking about.

[JS550]

Install isnt hard. The brake fluid fill up..looks harder than it is. With the bike on the side stand & handle bars turned, its about right.

[speedknot]

Yes, & mine is a 750. Wouldn't think yours would be too different though? Here are a few pics. One of my controls actually had the wires coming out of the bottom already, but I had to notch the other.
jim

Must be fun fillin up that brake fluid reservoir on those clubmans...

I'm thinking of ordering club man bars for my 550, so on a scale of 1-10, 10 being most difficult, how hard are they to install? I have never removed my handle bars so I'm not sure what wiring you guys are talking about.

Removing the bars isn't a problem.  Its rerunning the wiring that is a bit of a PITA.  The original bars had the bar control wiring running internally from the bottom of the control mount out to the center of the bar between the triple tree mounts.  The question I was posing was that how do I run the wiring so it looks nice and clean with my new clubmans.

[Quorthon]

Sorry for the IM confusion, didn't realize who you were.

Didn't take any of the process.   Here is one of it together though....





Nice and clean is running them internal, kind of clean is external.   It is not that hard to do.   Just pull the wires apart at the headlight and pull em out, then do what I said above.

Fluid reservoir is no big deal.

[JS550]

Aaaa...I see. Yeah the wires aren't that bad to do. Be careful pulling them out of your old bars so as not to break any!

[Dave-and-his-550]

One of my controls actually had the wires coming out of the bottom already, but I had to notch the other.

Ah ya, the wiring on the left side does go along the outside of the handlebar through the clutch lever, but the wiring on the right, with the starter button, goes inside the bar and out the center hole by the triple tree.

Meh, would be cool to run the wiring inside the bars, but my bike is so ratty and dirty anyway, I don't think anybody would give a hoot lol

Anybody got a link for clubman bars that are a good price, and good quality? I really wanna order 'em.

[jesus freek]

Ebay motors all day, I do my shopping at crc2onlinecatalog.com. good deals and good peeps. Good luclk

[Quorthon]

Here are some more.  Hope they help.

[Dave-and-his-550]

Here is a nice pictorial thread on a dude who installed clubman bars. He mentions little tabs on the stock controls that he broke off. He later said those tabs fit into holes in the stock bars that prevented the controls from sliding around on the bar.

Is this something you guys are familiar with? I'll have to take my bar and controls off and have a look for myself.

Also, what size clubman bars are you using Invisible? Is there a standard size that fits best for CB550 that wont hit the tank? Or is it just a matter of how you mount them?

Here is that pictorial thread on drilling clubmans:

http://www.austincaferacer.com/2008/07/installing-clubman-bars-the-hard-way/

[Quorthon]

I believe all 7/8 clubmans are the same, although I may be mistaken, someone else?


I used a similar method although I only used one oblong hole in the center like the stock bars, looks cleaner and is not any harder to do.  I would also make the holes a little bigger than he appeared to, like the stock bar holes.   

Lots of grease and two people makes all the difference!

[Dave-and-his-550]

This must be standard dimensions then?

[speedknot]

Ive seen bars with dimensions similar to the ones in the above pic, give or take an inch or so.

[Fishheadbaby]

Just put clubmans on my 400f last month - it is a bit of work - I initially was going to drill holes in the new clubman bars to run the wires internally - then realized that there's no way they are getting around that v-bend!!!
So I used a couple round and flat files to put a half moon shaped notch into the handlebar controls just big enough to fit the wire bundle through.  As someone mentioned before - there ARE little stems on the controls for the 400F (though I don't think 750s or smaller bikes have them - I've put on a lot of clubmans  ) that fit into holes in the bars and that you have to snap off with a pair of needlenose pliers - just takes a second. 
But what I wanted to say was PAY ATTENTION to your front brake line - clubman bars tend to move it in such a way that the cable kinks up into a sharp u-bend and serious limits your braking.  I disconnected the line and rerouted it so it was straighter and functioned properly- also rerouted the throttle cable as well.  All in all takes a little longer than you think its gonna -
All worth it though - makes the bike look 1000% better!!

[JS550]

Actually I do remember those stems on my 550 and 750. Snapped them off on my 550 & with my 750 realized that if you grab theb with vicegrips they  just pull out!

[736cc]

Notch the controls and run wires outside. Use a V45 Magna circa 1982 master cylinder so the brake fluid sits level w/ ground.
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[Laminar]

The '83 Nighthawk 550 also had a tilted master cylinder and a single disc, so that's another option.

[Joel]

How about running them internally up to the sharp bend and putting the exit hole at the bend?