Topic: Wires in Handlebars

[drag-on]

I give up.... How do you get wiring out of the stock bars to install drag bars?   

[Gordon]

Disconnect all the wires where they connect inside the headlight bucket and then pull the wiring out along with the switch pods. 

[drag-on]

Ok, thank you sir.... Was not sure what end to go from, looked like the other ends would not fit through, they have clips on them at top controls.

[ev0lve]

I give up.... How do you get wiring out of the stock bars to install drag bars?   

Carefully?

Bars in between your legs - pull one side while shoving it through with the other hand trying not to curse your maker. Some WD-40 might help on the side coming through.

If you've got two people it's probably easier.

[drag-on]

This is to cool, having my own tech guys on here,    Your right, all diconnected, glad they are color coded, what a nest inside lamp bezel. Ok gotta pull them out of bars as you said.

                  Thank you VERY MUCH...........

[Gordon]

The really fun part is getting them back in!

[slowjo]

I just finished up mine. It is easier getting the wires out while the bar is still on the bike. Pushing and pulling at the same time should work.

[Johnie]

I have done a lot of bars. Just take your time and have patience. Some are real stubborn and then I leave for a day and work at it later. I use some silicone on the stubborn ones but WD40 is good too. I have also used a hair dryer to soften up the protective wrap on the wires that are in the bars. It lets them bend around those curves easier. You have to inch them along. Pull a little at the top, then push a little from the bottom, pull that slack up from the top, push from the bottom again...you get the picture. For putting them in be sure the wire ends are straight. I tie a piece of strong string on them to help pull the wires through. Again, push and pull technique a little at a time.

[drag-on]

HOLLY CRAP... what a fight, the tubing around them was all bunched up. NEVER again... I would rather wet sand a wild cats a$$ while locked in a phone booth than to do that again. They are out, now that I'm all sweat....

              Thank you,

[drag-on]

Oh no    NO HOLES in the new drag bars........... Looks like more fun.

[Gordon]

Oh no    NO HOLES in the new drag bars........... Looks like more fun.

If you don't mind altering your stock switch pods, just cut a notch in the bottom half of each one and run the wires externally.  I do that to all my bikes because I tend to switch handlebars a few times before settling on one.  It turns swapping out bars into a ten minute job. 

[Gordon]

A couple of problems you're going to run into with the drag bars:

Control cables and brake line are either going to need to be replaced with shorter versions or re-routed to take up the slack.

Unless you found longer than 28" drag bars you're going to have issues with getting the throttle grip and master cylinder to fit because of where the tachometer is mounted.  

[drag-on]

Well your both right, cables to long. And I already made new holes in bars. Never thought of a notch. And to the guy who said feeding the wires back in was the fun part..... he was soooo right.   Oh and the throtle side was real fun.... Two push pull cables on it ?

[drag-on]

Need help again please.... Everything works but horn. Has two wires a black and a pale green. At the headlight bezel I see no pale green to plug in to.

[TwoTired]

Pale green goes to the bar push button.
The button provides gnd when pushed.  The Black wire is +12v from the Keyswitch.

[drag-on]

ok.... but where they plug in to headlight bezel wires..... I have the black pluged to black, but the pale green has no other pale green to plug it in to in bezel. I'm connected at switch, never touched that end of wiring.

[Don R]

Follow the wire up from the horn and see where it goes. One wire the horn is hot (black)and the other wire goes into the headlight bucket to connect to your pale green to make the ground on the switch.

[drag-on]

ok, got that, now my brake light.... engine off, key on first click,, light bright, step on brake light a bit dimmer.... just the reverse of should be..... Ground    

[drag-on]

Ok.... History here, I am a fabrication guy, a custom paint guy, and a 2 stroke motor guy, I have NO IDEA about wiring electrics.

I have ONE pale green wire coming out of horn button, it leads in to the headlight bezel. I have NO pale green in headlight bezel to connect it to.   

[TwoTired]

Maybe there is something unique about the year and model of bike you have.
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(Whatever that is....)

[drag-on]

Thank you VERY much..... I got it, guess what, the one wire was faded in color,  .... got it now though.........


          Thanks buddy.............

[Don R]

Well then just Drag-on then! Good job.

[Deltarider]

For wiring concerning your horn first of all identify your bike precisely, including area code. Then look for the appropiate wiring scheme. My CB500 owners manual contains no less than four different wiring schemes (ED, General, UK and USA). Wiring for horns differ for some area code's.