Topic: superbike bars w/ internal wiring

[nomad]

I've looked around and didn't see anything like this, but can someone tell me if anyone makes a set of superbike bars that are already punched for internal wiring?  I guess I could drill the holes, but would rather not.

If drilling my own is the only option, what's the best way to go about it other than simply drilling and filing the edges?  Thanks.

[DarcyCB400F]

Not sure if this helps but here goes anyway... 

The factory bars on the '77 CB400F are wired internally...

[nomad]

Not sure if this helps but here goes anyway... 

The factory bars on the '77 CB400F are wired internally...

The factory bars on my '74 CB750K were wired internally too...

[Grabcon]

Ideally a milling machine would help, but for most of us a drill press or a hand drill are in order. Drilling the holes is not the issue, it is getting all of the burrs out from the inside of the holes. Those burrs will cause great electrical grief.

I opted to grind out the controller on each side and run the wires on the outside. It may not look as clean but it is simple and there will be not electrical issues.

[DavePhipps]

Not sure if this helps but here goes anyway... 

The factory bars on the '77 CB400F are wired internally...

The factory bars on my '74 CB750K were wired internally too...

The 400 bars are closer to superbike bars then the 750 high rise things.

[nomad]

Not sure if this helps but here goes anyway... 

The factory bars on the '77 CB400F are wired internally...

The factory bars on my '74 CB750K were wired internally too...

The 400 bars are closer to superbike bars then the 750 high rise things.

Ohhhh, ok.  Not having any familiarity with the CB400's left me scratching my head.  Thanks for cluing me in. 

[MCRider]

Drilling the bars is not so hard once you get to it. Use the old bars for a template. Centerpunch and drill 2 holes near each other then connect them and file or Dremel them into an oval. One small hole for the locating peg. A hand held drill will do it if the bars are in a vise or suitable holder. Sharp bits always help.

[vames]

Those little cutting wheels on a dremel will cut a nice clean line between two drilled holes.

[Hinomaru]

OK, it's not a true Superbike bar, but the Flanders "Cafe Style Bar" is very close to the original Honda "Euro" bars pictured below. The Flanders bar has internal wiring holes and are knurled. They do not come cheap, but your original K4 clutch & throttle cables fit nice. The upper brake hose will need to be shorter for a clean fit that looks factory.  

Part number: 650-01071 on page 35:
http://www.sideroadcycles.com/HandlebarCatalog1-28-2011.pdf



Here's a pic of my original Honda 750K Euro bars for comparsion:

[nomad]

OK, it's not a true Superbike bar, but the Flanders "Cafe Style Bar" is very close to the original Honda "Euro" bars pictured below. The Flanders bar has internal wiring holes and are knurled. They do not come cheap, but your original K4 clutch & throttle cables fit nice. The upper brake hose will need to be shorter for a clean fit that looks factory. 

Part number: 650-01071

http://www.SideRoadCycles.com/ImportedMotorcycles/ImportHandlebars/ImportStreet/78StreetWire.html

Wow!  $110.95!!!  Besides the cables fitting nicely, what makes this bar cost that much?  Is it made from some special, space age alloy?  Like you said... pricey.   BUT, it does seem to fit the bill on what I'm looking for.  I guess at this point, the wife shouldn't flinch too much at another $100+ part.    Then again...

[Hinomaru]

Well, Flanders bars are considered by some to be the "Holy Grail" of handlebars and you're probably paying for the name. Being made in the USA adds to the price too. My personal experience shows them to be a high quality part right down to the chrome plating. I've also "heard" that they are harder to bend when your bike falls over.

http://www.flandersco.com/

[Really?]

I got the wires in momma's bars.  Used a dremel and a drill to make all the holes.  Not too much work to do it either.  If you make a small mess, no matter, the controls will cover them up.

I used a 3x5 card.  I wrapped it and cut out the holes.  Used those to mark the other bars.  Worked out very well.

[cobrajunkie]

Ideally a milling machine would help, but for most of us a drill press or a hand drill are in order. Drilling the holes is not the issue, it is getting all of the burrs out from the inside of the holes. Those burrs will cause great electrical grief.

I opted to grind out the controller on each side and run the wires on the outside. It may not look as clean but it is simple and there will be not electrical issues.

I need to drill my bars soon as well and the burrs have been a concern.  I have 12" rat tail file I plan to use.  Any other ideas for removing the burrs left by drilling?

[flybox1]

Ideally a milling machine would help, but for most of us a drill press or a hand drill are in order. Drilling the holes is not the issue, it is getting all of the burrs out from the inside of the holes. Those burrs will cause great electrical grief.

I opted to grind out the controller on each side and run the wires on the outside. It may not look as clean but it is simple and there will be not electrical issues.

I need to drill my bars soon as well and the burrs have been a concern.  I have 12" rat tail file I plan to use.  Any other ideas for removing the burrs left by drilling?

a silicon carbide grinding bit for your dremel/ hand drill.
should speed things up a bit.

[wannabridin]

Hop on amazon and get a pipe deburring tool.  That'll clean up things nicely.  Then don't forget to get a rubber grommet if you can, that'll help all but eliminate wires rubbing.

[nomad]

Then don't forget to get a rubber grommet if you can, that'll help all but eliminate wires rubbing.

I wonder if Plasti Dip painted on around the perimeter of the hole would work?

[wannabridin]

I don't see not, but youd probably need to wrap it around at least the id or od of the bars, otherwise I see it rubbing off.  Grommets are clean and simple!

[nomad]

I don't see not, but youd probably need to wrap it around at least the id or od of the bars, otherwise I see it rubbing off.  Grommets are clean and simple!

I was just thinking that a grommet for an oval, custom cut hole would be hard to come by.  The round holes up near the grips would be easy to get grommets for.  Is there a source for oval grommets?

[MCRider]

There may not be room for a grommet. I'd just clean the burrs up real good and go on.

[wannabridin]

http://www.rubbergrommets.com/products/search.php?product=grommets

i don't know about the oval grommets.  i'm probably going to go this route just because i'll have minimal wiring going through my bars.  (DCC switch housing, no starter, brake line switch.)

[Scott S]

 I understand the actual cutting/drilling part, but I'm still unsure about marking the holes in the correct spot.

 I have a set of 400F bars, but they're just too narrow for me. I was going to drill another bar, but don't know how to get the holes marked so that the controls aren't rotated too far forward or back one the bars are mounted.....am I making sense?

[Really?]

Yes, use the cards like I recommended up above.  After you have the holes in the card punched out, also mark the card at 12 o'clock.  Decide where you want the new bars, cut the holes out in the cards and use a marker or something to mark where you are going to make holes on the bars.

If you need to, you can always oblong the the hole for the pin to get a little more rotation out of it.  It really does not take much.  And you will have enough wire to make up for the small difference.

Hope that makes sense.

[robdrobd]

I understand the actual cutting/drilling part, but I'm still unsure about marking the holes in the correct spot.

 I have a set of 400F bars, but they're just too narrow for me. I was going to drill another bar, but don't know how to get the holes marked so that the controls aren't rotated too far forward or back one the bars are mounted.....am I making sense?

I think I have a pair of 76 750f bars and a pair of 77 400f bars. If the 400f bars you have are from a 75 or 76 I will trade straight up or even add cash to the deal if needed. I want the narrow, lower profile bars for my 77 400f. Let me know, thanks.

[flybox1]

wrap your bars in painters tape first.
then, using TipperT's card trick, trace your cutout on the tape with a sharpee then go to work