Topic: How to remove throttle from CB500? (Installing Clubmans)

[KCRSXTypeS]

Hey guys, I am in the process of installing clubmans and the only part I have left to do is remove the throttle from the right side of the handle bar.  Im having trouble getting it off so I can remove the whole handlebars...what am I doing wrong?

[Gordon]

You still have the stock bars on with the wires running through them? 

[KCRSXTypeS]

yes and no...they are kinda just hanging there.  All the wires are still in the headlight housing, the clutch cable and brake line are disconnected but the other wires and throttle cables are still attached.

[Gordon]

I don't understand.  Are the wires for the switches and starter button running through the bars or not? 

[KCRSXTypeS]

Yes, the wires for the switches are running through the stock bars and the stock bars are still on...people talk about how to install clubmans but never give instructions for removing stock bars lol.

[Gordon]

You need to disconnect the throttle cables at the carbs, and then disconnect them from the inside of the throttle grip.  Once you've done that and you have unplugged all of the corresponding wires inside the headlight bucket you should be able to pull the throttle grip off and pull the wires out along with it. 

[Gordon]

It helps a lot if you feed the wires in from the back as you're pulling.

[KCRSXTypeS]

grrrrrr...was hoping to not have to remove the cables at the carbs...I guess its the easiest way though...its just a pain in the ass to get the cables back into the carbs later.

[Gordon]

If you're installing clubmans you're going to have to either re-route the throttle cables or replace them with shorter ones anyway.  Same with the brake and clutch lines.

[Gordon]

Oh, and you'll have to cut out a notch in the bottom half of each switch pod to run the wires externally, too.  And either drill holes in the bars for the switch pod locating pins or just pull the pins out.

Switching to non-stock handlebars for the first time is never as simple as you think it will be.  It can easily turn into a full day or even a weekend project if you're not experienced at it. 

[Gordon]

Am I being a wet blanket again?

[KCRSXTypeS]

Didn't have to notch the handle bars...ran them out the end right before the bend, and the stock throttle cables and brake lines I made work just fine.  Rides great!  Took me about 6 hours which would have only been about 4 had I had a good drill and didn't have to wait for mine to recharge...

[Gordon]

Sweet!  You were much faster than I was the first time.  

[KCRSXTypeS]

Sweet!  You were much faster than I was the first time.  

That's what she said...